Datasheet
BATTERAY™ ZETA PRO is a high-capacity automated battery sorting system designed for large recycling facilities that process mixed streams of used portable batteries at industrial scale.
Built on the proven BATTERAY™ X-ray sorting technology, BATTERAY™ ZETA PRO combines optical recognition, X-ray inspection, and AI-driven classification to identify battery chemistry by internal structure and visible characteristics.
The system is engineered for continuous high-volume operation, with automated material handling, multi-stream sorting, recirculation of unrecognized batteries, and integration capabilities for modern recycling plant infrastructure.
BATTERAY™ ZETA PRO is the highest-capacity platform in the BATTERAY™ ZETA line, developed for facilities that require higher throughput, cleaner output fractions, and a greater level of process automation.
| System Focus | Technology | Automation | Best Application |
|---|---|---|---|
| High-capacity sorting | Optical + X-ray battery recognition | Automated industrial architecture | Large recycling plants processing high volumes of mixed portable batteries |
| Fraction purity control | AI-supported chemistry classification | Up to 9 sorting groups per session | Reducing contamination between battery chemistry groups |
| Continuous operation | Return conveyor and recirculation architecture | Automated re-check of unrecognized batteries | Industrial workflows where downtime and manual re-sorting must be minimized |
For recycling operators, BATTERAY™ ZETA PRO provides a scalable route from battery identification to high-capacity automated sorting, helping turn complex mixed waste streams into cleaner and more predictable material fractions.
The core difference of BATTERAY™ ZETA PRO is its industrial sorting architecture. The system is designed not only to recognize battery chemistry, but also to maintain continuous material flow, reduce manual intervention, and support large-scale battery recycling operations.
Optical analysis and X-ray inspection work together to collect data from both the outside and inside of each battery. AI-driven software then classifies the battery according to the selected sorting program and directs it to the appropriate output stream.
BATTERAY™ ZETA PRO also includes an automated recirculation loop for batteries that cannot be classified with sufficient confidence during the first pass. These batteries can be returned for additional inspection, helping protect sorted fractions from contamination.
Advanced sub-classification of Li-ion batteries, including LMO, NMC, and LFP, is part of the ongoing R&D roadmap. The BATTERAY™ ZETA PRO architecture is designed to support future development in this direction, but current project specifications should always be confirmed with the LINEV Systems technical team.
- High-capacity automated battery sorting for large recycling plants and industrial processing lines
- Optical + X-ray recognition for classification based on visible characteristics and internal structure
- AI-supported chemistry classification for mixed streams of portable batteries
- Up to 9 sorting groups per session for multi-stream output control
- Automated recirculation loop for unrecognized batteries requiring additional inspection
- Designed for plant integration with industrial communication and process control requirements
Software Capabilities
- Machine-learning classification based on optical and X-ray inspection data
- Expanded battery database for complex mixed recycling streams
- Custom sorting programs selected according to the required recycling process
- Statistics and error logging for monitoring system performance
- Support for industrial process supervision and integration into automated recycling workflows
Supported 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-Primary)
- Lithium Thionyl Chloride (Li-SOCl₂)
- Lithium Manganese Dioxide (Li-MnO₂)
- Lithium Iron Disulfide (Li-FeS₂)
Classification Structure
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 | + |
Process Overview
Step 1. Batteries are loaded into the high-capacity feeding system and pass through the vibrating screen, where small waste, dust, fragments, and undersized items are separated from the main stream.
Step 2. Prepared batteries move through the inspection section, where optical recognition and X-ray imaging collect data on visible characteristics and internal structure.
Step 3. AI-supported software analyzes the inspection data and assigns each battery to the required chemistry group according to the selected sorting program.
Step 4. Identified batteries are directed into the appropriate output stream. Batteries that cannot be reliably classified are routed through the automated return conveyor for additional inspection.
- Throughput up to 40,000 batteries/hour
- Nominal throughput up to 1000 kg/hour
- Sorting purity of 99.5% for Alkaline and Zinc-Carbon batteries
- Over 98% sorting purity for Ni-Cd / NiMH groups
- Up to 9 sorting groups per session
- Automated recirculation loop for unrecognized batteries
Key features
AI-Driven Multi-Sensor Recognition
BATTERAY™ ZETA PRO combines optical recognition, X-ray inspection, and machine-learning algorithms to classify batteries by internal structure and visible characteristics.
Improved Ni-Cd / Ni-MH Separation
Enhanced recognition tools support high-purity sorting of nickel-based batteries, helping recyclers reduce contamination between Ni-Cd and Ni-MH fractions.
Automated Recirculation Loop
Unrecognized batteries can be automatically returned for additional inspection, helping maintain cleaner output fractions without interrupting the main sorting flow.
High-Purity Battery Sorting
Sorting purity reaches 99.5% for Alkaline and Zinc-Carbon batteries, over 98% for Ni-Cd / NiMH, and over 95% for other supported groups.
High-Capacity Throughput
Designed for large recycling plants, BATTERAY™ ZETA PRO supports up to 40,000 batteries per hour and nominal throughput up to 1000 kg per hour.
Industrial Line Integration
BATTERAY™ ZETA PRO is designed for integration into automated recycling workflows with supervised operation, process monitoring, and industrial control compatibility.
Technical data
X-ray source
| X-ray emission | Complies with the standard: 1 μSv/h at any accessible point at a distance of 10 cm from the external surface of the system |
| X-ray protection | Full operator protection |
Loading
| Loading hopper capacity | up to 600 kg |
| Loading hopper volume | 420 L |
| Productivity of pure fractions | up to 40,000 batteries/hour |
| Nominal throughput | up to 1000 kg/hour |
| Sorting groups per session | up to 9 |
| Pneumatic | 10 bar ±10%, ≥500 SLPM |
Dimensions
| Overall dimensions (maximum) | ||
|---|---|---|
| Length | 11800 mm | |
| Width | 3200 mm | |
| Height | 2600 mm |
| Layout | 18000 x 9000 mm |
|---|
| Weight (maximum) | 4200 kg |
|---|
Purity
| Zinc-Carbon, Alkaline | 99.5 % |
| Ni-Cd / NiMH | >98 % |
| Other groups | >95 % |
X-ray source
| X-ray emission | Complies with the standard: 0.1 mrem/h at any accessible point at a distance of 4 in from the external surface of the system |
| X-ray protection | Full operator protection |
Loading
| Loading hopper capacity | 1323 lb |
| Loading hopper volume | 111 gal |
| Productivity of pure fractions | up to 40,000 batteries/hour |
| Nominal throughput | up to 2205 lb/hour |
| Sorting groups per session | up to 9 |
| Pneumatic | 145 psi ±10%, ≥17.7 SCFM |
Dimensions
| Overall dimensions (maximum) | ||
|---|---|---|
| Length | 38.7 ft | |
| Width | 10.5 ft | |
| Height | 8.5 ft |
| Layout | 59 x 29.5 ft |
|---|
| Weight (maximum) | 9260 lb |
|---|
Purity
| Zinc-Carbon, Alkaline | 99.5 % |
| Ni-Cd / NiMH | >98 % |
| 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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