Datasheet
BATTERAY™ is an automatic X-ray battery sorting system designed for recycling facilities processing mixed streams of used portable batteries. The system identifies battery chemistry by analyzing internal structure rather than relying on labels, markings, color, or external condition.
This approach is especially important when batteries are corroded, counterfeit, damaged, or unmarked. BATTERAY™ helps recyclers reduce sorting errors, improve output fraction purity, and lower the risk of contamination in downstream recycling processes.
BATTERAY™ provides reliable X-ray battery sorting for core recycling workflows where accurate chemistry identification and stable sorting purity are required.
The core advantage of BATTERAY™ is its ability to inspect the internal structure of each battery using X-ray imaging. Instead of relying on surface labels or visual appearance, the system analyzes structural and material characteristics directly related to battery chemistry.
Machine-learning algorithms assist battery recognition and allow operators to expand the database when new brands, formats, or battery types appear in the recycling stream.
- Identifies battery chemistry using internal X-ray structure analysis
- Supports classification of unmarked, corroded, and counterfeit batteries
- Designed for automated battery sorting with operator-assisted control
- Adaptable to evolving recycling streams through expandable software database
Software Features
- Standard sorting using the default battery classification map
- Sorting with customer-added batteries using the default map plus customer database
- Semi-automatic database expansion for previously unrecognized batteries
- Custom sorting programs selectable for specific recycling workflows
Sort map
| ZnC | Alk | NiCd / NiMH | NiCd | NiMH | Li-Primary | Li-SOCl₂ | Li-MnO₂ | Li-FeS₂ | Li-Ion | |
| AAAA (LR61) | + | + | ||||||||
| AAA (R03) | + | + | + | + | + | + | + | + | + | |
| AA (LR6) | + | + | + | + | + | + | + | + | + | + |
| C (LR14) | + | + | + | + | + | + | ||||
| D (LR20) | + | + | + | + | + | + | + | + | ||
| 6F22 (9V) | + | + | + | + | + | + | ||||
| A23 | + | |||||||||
| A27 | + | |||||||||
| CR2 | + | + | + | |||||||
| 16340 (CR123) | + | + | + | + | ||||||
| 14250 (1/2 AA) | + | + | + | |||||||
| 18650 | + | |||||||||
| 21700 | + |
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Sorting battery groups:
- Zinc–Carbon (ZnC)
- Alkaline (Alk)
- Nickel-Cadmium (NiCd)
- Nickel-Metal Hydride (NiMH)
- Mixed NiCd / NiMH group
- Lithium-Ion (Li-Ion)
- Lithium Primary: Li-SOCl₂, Li-MnO₂, Li-FeS₂
Process overview
Step 1. After the operator loads batteries into the hopper, they move through the first conveyor where small debris, dust, broken battery parts, and miniature batteries are separated from the main stream.
Step 2. Batteries then pass through the X-ray inspection zone where BATTERAY™ analyzes their internal structure.
Step 3. The AI-assisted classification system assigns each battery to the appropriate chemistry group according to the selected sorting program.
Step 4. Pneumatic injectors direct each identified battery into the corresponding output container. Batteries that cannot be recognized are directed to a separate container for additional inspection.
- Throughput up to 18,000 batteries per hour
- Sorting purity up to 99.5% for Alkaline and Zinc-Carbon batteries
- Over 95% sorting purity for other supported battery groups
- Sorting into up to 6 battery chemistry groups
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Key features
Unmarked Battery Detection
BATTERAY™ identifies batteries by internal structure, allowing reliable classification even when labels are missing, damaged, or misleading.
X-Ray Battery Inspection
Low-dose X-ray imaging analyzes the internal geometry and material composition of each battery to determine its chemistry.
Industrial Sorting Throughput
Automated conveyor architecture enables sorting performance of up to 18,000 batteries per hour and up to 350 kg per hour.
High Sorting Purity
Sorting purity reaches up to 99.5% for Alkaline and Zinc–Carbon batteries and over 95% for other supported chemistries.
Sorting into 6 Battery Groups
Automatically separates mixed battery streams into six chemical groups including Zinc–Carbon, Alkaline, NiCd, NiMH, Li-Ion and Primary Lithium.
Proven BATTERAY™ Technology
Patented X-ray battery sorting technology developed by LINEV Systems and deployed at recycling facilities across multiple continents.
Technical data
X-ray source
| X-ray emission | Complies with the standard: 1 μSv/h at any point at a distance of 10 cm from the device. Typical value of our system less than 0.3 μSv/h |
| X-ray protection | Full operator protection |
Loading
| Loading hopper capacity, up to | 350 kg |
| Loading hopper volume | 250 L |
| Conveyor speed | 1.0 m/s |
| Productivity of pure fractions | up to 18,000 batteries/hour |
| Pneumatic | 10 bar ±10%, ≥500 SLPM |
| Throughput capacity | up to 350 kg/hour, material-dependent |
Dimensions
| Overall dimensions (maximum) | ||
|---|---|---|
| Length | 7960 mm | |
| Width | 2690 mm | |
| Height | 2400 mm |
| Layout | 15000 x 8000 mm |
|---|
| Weight (maximum) | 2400 kg |
|---|
Purity
| Zinc-Carbon, Alkaline | 99.5 % |
| Other groups | >95 % |
X-ray source
| X-ray emission | Complies with the standard: 0.1 mrem/h at any point at a distance of 4 in from the device. Typical value of our system less than 0.03 mrem/h |
| X-ray protection | Full operator protection |
Loading
| Loading hopper capacity, up to | 772 lb |
| Loading hopper volume | 66 gal |
| Conveyor speed | 3.28 ft/s |
| Productivity of pure fractions | up to 18,000 batteries/hour |
| Pneumatic | 145 psi ±10%, ≥17.7 SCFM |
| Throughput capacity | up to 772 lb/hour, material-dependent |
Dimensions
| Overall dimensions (maximum) | ||
|---|---|---|
| Length | 26.1 ft | |
| Width | 8.8 ft | |
| Height | 7.9 ft |
| Layout | 49.2 x 26.2 ft |
|---|
| Weight (maximum) | 5291 lb |
|---|
Purity
| Zinc-Carbon, Alkaline | 99.5 % |
| Other groups | >95 % |
Reviews and related links
Mixed streams of used portable batteries are difficult to sort reliably when labels are damaged, missing, or misleading. Manual inspection and surface-based recognition can lead to sorting errors, cross-contamination, and lower-value output fractions.
BATTERAY™ solves this problem by using X-ray battery inspection to analyze the internal structure of each battery. Instead of depending on color, label, or external condition, the system identifies battery chemistry by structural and material features inside the cell.
This technology supports automatic battery sorting into key chemical groups, helping recycling facilities improve sorting purity, reduce manual dependency, and protect downstream recycling processes from contamination.
Learn how X-ray battery sorting technology helps recyclers identify used batteries more accurately and turn mixed battery waste into cleaner, more valuable material fractions.
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