Pioneers mapping the future of smart sorting

The sensor-based sorting market globally is gaining momentum, offering a rare growth opportunity in a volatile economy. As well as recovering critical metals, there are new ways to target plastic, construction and textile waste.

The recent sensor-based sorting & control conference in Aachen made on thing clear; we have only glimpsed the true potential of smart sorting. This sector is already worth EUR 155 million in Germany alone. Market analysts expect the figure will almost double by 2033.

Speakers and delegates agreed that the future requires recycling tech specialists and industry partners to further explore sensor fusion. This way, they will be able to channel the full range of smart sorting solutions, not just artificial intelligence (AI).

Raptor for mixed metals

Markus Dargel, project engineer at Laser Analytical Systems & Automation (LSA), is currently examining the characteristics of mixed metal scrap. His work focusses on improved steel and metal recycling through better separation of unwanted tramp material and valuable alloying elements.

‘There is a long way to go when talking about enhancing sensor-based sorting. Did you know a sorting line can contain up to 95 sensors? That’s a lot of sensors, so a lot of variables and measuring points.’

LSA is based in Aachen and was established in 2004 as a spin-off of the Fraunhofer Institute. ‘My team is particularly excited about being part of the EU-funded R&D project called MEDALS,’ says Dargel. ‘We aim to achieve a recovery rate for mixed metals of at least 90% by reducing tramp elements by 60-70% and boost sorting efficiency by 50%.’

Geometric profiling

Led by the Swedish KTH Institute, eight industry partners have joined forces. Speaking to LSA’s contribution, Dargel explains its machines allow for geometric profiling. The unit being tested is called the Raptor, which averages one pick per second. It features two robotic sorting units targeting both small fractions and those more than 1kg.

The existing system has four robot grippers and it can be scaled up to 12. The conveyor speed is running at 1.1 metres per second, with a throughput of 2.5 to nine tonnes per hour, detecting a grain size of 16-120mm with 90-99% accuracy, depending on how many grippers are installed.

‘We want to support excavator operators by providing data in real time,’ Dargel notes. He says the sorter is well-suited as an infeed conveyor unit for shredders. LSA also wants to put an inspection unit above the conveyer to enable controlled line analysis for batch operation.

Next phase

Discussing 3D imaging results, he points out: ‘We can do an in-depth piece-by-piece spectra analysis and the whole system is covered, so it is dust protected. We’re heard good things about the Delta robots that have been deployed at various facilities in Europe.’

Building on this, Dargel’s team has will complete further experiments in the coming months. ‘Field tests will be completed this summer. I think this approach has far-reaching potential for high quality metals recycling.’