BATTERAY ZETA · Intelligent Multi-Chemistry Battery Sorting

X-Ray Battery Sorting Technology

BATTERAY™ ZETA uses high-resolution X-ray inspection to examine the internal structure of individual batteries. X-ray images provide information about component arrangement, internal geometry, and material-related characteristics that can help distinguish chemical groups even when batteries share similar external shapes or markings.

AI-based recognition interprets this information according to the active sorting program. Supported batteries are assigned to designated chemistry groups, while uncertain or unsupported objects can be directed to a separate review or residual route. Classification results are translated into controlled pneumatic sorting actions, producing defined output fractions rather than simply identifying objects on the conveyor.

This approach is particularly valuable for mixed recycling streams containing visually similar, corroded, unmarked, or moderately damaged batteries within validated operating conditions. For a detailed explanation of the technology, visit X-ray Battery Sorting Technology.

Dedicated Ni-Cd / Ni-MH Separation

Nickel-cadmium and nickel-metal hydride batteries may look similar but require different downstream recycling processes. Their reliable separation is therefore important for reducing cross-contamination and improving the quality of recovered material fractions.

BATTERAY™ ZETA supports additional sorting of a previously separated mixed Ni-Cd / Ni-MH fraction. During a dedicated second X-ray sorting pass, a specialized recognition program separates supported nickel-cadmium and nickel-metal hydride batteries into individual output streams.

Reference output purity exceeds 98% for supported battery types under validated conditions. The separation program, applicable formats, and achievable output quality are confirmed according to the customer’s material stream and sorting requirements.

Refined Through Real Industrial Experience

BATTERAY technology has evolved through practical experience at European battery recycling facilities. Real production conditions have provided engineering feedback that has helped improve not only chemistry recognition, but also material handling, maintenance, industrial automation, and process integration.

Germany — Industrial Plant Integration. At a recycling installation in Germany, BATTERAY equipment was integrated into an existing automated sorting line. Plant-control functions, software, safety settings, and operating parameters were adapted to the facility’s production requirements. This demonstrated how X-ray battery sorting can function as an integrated stage of a larger industrial recycling process.

Netherlands — Challenging Battery Streams. At a recycling facility in the Netherlands, incoming material included heavily deformed batteries, attached wires, contacts, and foreign objects. Engineering improvements included modified conveyor components to help reduce blockages and simplify cleaning, together with additional X-ray / AI recognition algorithms for supported damaged and wire-containing batteries.

These developments reflect an engineering approach shaped by actual customer requirements. The improvements were implemented in specific industrial projects; their availability and performance in new BATTERAY™ ZETA installations depend on the selected configuration and application validation.

Software & Industrial Integration

BATTERAY™ ZETA combines AI-based chemistry recognition with software tools for automated sorting control, production monitoring, and application-specific configuration. The system can be adapted to coordinate with existing recycling infrastructure and plant automation requirements.

• AI-based X-ray recognition and configurable battery chemistry sorting programs
• Battery recognition database supporting application-specific classification requirements
• Production statistics, operating information, and diagnostic error logging
• Supervised automatic operation with operator monitoring and process control
• Industrial communication interfaces and plant-level integration where specified
• Customer-specific material handling and sorted-battery discharge arrangements
• Software and recognition improvements developed from field operating experience

Process Overview

Step 1 — Feeding and Preparation. Prepared loose batteries are loaded into the hopper and transferred through the conveyor system. Small debris, dust, broken battery parts, and unsuitable miniature objects can be separated from the main stream according to the configured feeding arrangement.

Step 2 — X-Ray Inspection. Individual batteries move along the orientation conveyor and pass through the inspection area. High-resolution X-ray imaging captures internal structural and material-related information for subsequent chemistry identification.

Step 3 — AI Classification. Intelligent recognition algorithms analyze the X-ray data and assign supported batteries to the appropriate chemistry groups according to the selected sorting program and validated recognition parameters.

Step 4 — Controlled Sorting. Pneumatic ejectors direct identified batteries into designated collection fractions. Batteries that cannot be reliably classified or sorted follow an agreed residual, review, or re-sorting route.

Input Material & Performance Conditions

BATTERAY™ ZETA is designed for prepared streams of individual portable batteries. Standard feeding requirements address battery condition, contamination, foreign objects, and attached components. Processing of damaged, non-standard, or challenging materials must be evaluated according to the selected equipment configuration and validated operating conditions.

Reference throughput and output purity depend on battery composition, size distribution, physical condition, feed preparation, sorting programs, and system configuration. Purity values describe the quality of sorted output fractions rather than overall recognition accuracy. Actual performance and supported functions are confirmed in the applicable technical proposal.

For more detailed information about supported battery formats, sorting programs, and specialized lithium classification developments, visit the BATTERAY ZETA Series website.