TECHNOLOGY: BATTERAY X-ray Battery Sorting System
FOCUS: Automated battery identification and recycling
CONTACT: [email protected]
As the global demand for raw materials increases, so does the need for efficient and sustainable recycling solutions. The battery recycling industry faces unique challenges, from sorting the wide variety of battery chemistries to complying with evolving environmental regulations. At the forefront of this transformation is LINEV Systems, a leader in advanced X-ray inspection technologies, offering solutions that ensure the proper identification and safe recycling of used batteries.
Our Experience
LINEV Systems is an international innovator in the field of non-destructive testing (NDT) and X-ray imaging systems. Our experience spans multiple industries, from security to industrial applications, and we now leverage this expertise in the recycling sector.
Our mission is to provide state-of-the-art technology that not only meets the rising demand for raw materials but also ensures the safe and environmentally responsible disposal of used batteries.
Our patented BATTERAY technology is a key part of this effort. It helps battery recycling facilities automate the sorting process, improve the purity of recovered materials, and reduce operational risks such as fire or contamination. With growing concerns over battery waste, BATTERAY is designed to address the industry’s challenges head-on, providing an accurate and safe solution for recycling operations.
The Need for Efficient Battery Sorting
As the usage of portable devices, electric vehicles (EVs), and energy storage systems rises, so does the volume of used batteries entering the recycling stream.
Batteries come in various chemistries, including:
- Lithium-ion (Li-ion)
- Nickel-cadmium (NiCd)
- Nickel-metal hydride (NiMH)
- Alkaline
- Zinc-carbon
Each type has distinct characteristics and risks. Sorting these batteries manually is time-consuming, inefficient, and prone to error.
At the same time, stricter regulations across markets such as the EU, UK, and the United States require recycling operations to meet high standards of sorting purity and environmental compliance. This creates a strong need for precise, automated sorting technologies.
BATTERAY – Unique Automated Sorting Solution
To tackle these challenges, LINEV Systems developed the BATTERAY automated X-ray sorting system. Using advanced imaging technology, BATTERAY detects the internal structure of each battery and identifies its chemical composition with high precision.
Unlike traditional sorting methods that rely on labels, size, or external markings, BATTERAY literally “sees” inside the battery, enabling significantly higher accuracy.
The BATTERAY system operates through four key stages:
- Scanning – Each battery is scanned using a fan-shaped X-ray beam.
- Image Capture – X-rays passing through the battery are converted into digital images at two energy levels.
- Analysis – These images are analysed to identify the battery chemistry.
- Sorting – The system automatically sorts batteries into the correct categories.
This approach ensures accurate sorting even when batteries have damaged labels, corrosion, or counterfeit markings.
The system can identify multiple battery chemistries including:
- Lithium-ion (Li-ion)
- Lithium primary (Li-SOCl₂, Li-MnO₂, Li-FeS₂)
- Nickel-cadmium (NiCd)
- Nickel-metal hydride (NiMH)
- Alkaline (Alk)
- Zinc-carbon (ZnC)
Key Features and Benefits
BATTERAY delivers several critical advantages for recycling facilities, municipal waste centres, and e-waste operators:
- Increased Efficiency – Automated sorting reduces manual labour and improves throughput up to 350 kg per hour.
- High Sorting Purity – Up to 99.5% purity for alkaline and zinc-carbon batteries, and over 95% accuracy for other types.
- Safety and Compliance – Accurate sorting reduces fire risk and supports compliance with environmental regulations such as WEEE.
- Handles Compromised Batteries – Even damaged or corroded batteries are identified correctly thanks to internal X-ray analysis.
- Sustainability – Enables recovery of valuable metals and supports circular economy principles.
Why BATTERAY is a Game-Changer
The recycling industry is increasingly focused on sustainability, efficiency, and regulatory compliance. As battery recycling regulations become more stringent, advanced sorting technologies such as BATTERAY are becoming essential.
Thanks to its patented X-ray technology, BATTERAY offers a reliable and scalable solution for facilities handling large volumes of batteries.
The system is already deployed across multiple regions including Australia, the EU, Scandinavia, the United States, and Canada, where it has successfully sorted batteries for years. Clients report significant improvements in both sorting accuracy and operational efficiency.
The Impact on Recycling Operations
BATTERAY has significantly improved operations at facilities that previously relied on manual sorting. Many operators have achieved 99.5% sorting purity in key battery categories such as alkaline and zinc-carbon batteries.
This level of accuracy not only helps facilities meet environmental regulations but also improves profitability by maximizing the value of recovered materials.
By enabling the recovery of valuable metals such as nickel, zinc, and lithium, BATTERAY also plays an important role in supporting the global transition to a circular economy.
Future Outlook: Expanding Sustainability
As demand for battery recycling continues to grow—driven by electric vehicles and renewable energy storage—BATTERAY is expected to become an essential tool for the recycling industry.
The system is designed to adapt to emerging battery formats and chemistries, including those used in electric vehicles, ensuring its long-term relevance as recycling technologies evolve.
At LINEV Systems, we remain committed to developing innovative solutions that improve sustainability and operational efficiency within the recycling sector.
Conclusion
Our patented BATTERAY system represents an important step forward in battery recycling technology. By combining advanced X-ray imaging with automated sorting, BATTERAY helps recycling facilities increase safety, improve sorting accuracy, and recover valuable materials.
As battery usage continues to grow worldwide, the need for efficient recycling solutions will only increase. BATTERAY provides the precision and reliability needed to support recycling facilities, municipal waste operators, and the rapidly expanding electric vehicle industry.
Used batteries can be sorted into 6 different chemical groups