Reinventing Battery Sorting: Inside the Technology Behind BATTERAY ZETA

The global shift toward electrification is driving exponential growth in battery consumption—across consumer electronics, mobility, and renewable energy storage. But with this surge comes a critical challenge: how do we safely and efficiently sort the diverse and hazardous waste streams of used batteries at scale?

BATTERAY ZETA redefines what’s possible in battery sorting by combining advanced X-ray imaging, AI-driven material recognition, and modular classification logic. Designed for high-throughput industrial environments, this patented platform delivers the purity, safety, and scalability modern recycling operations demand.

The Problem with Conventional Sorting

Conventional battery sorting methods—whether manual, optical, or semi-automated—struggle with today’s realities. Labels are missing or misleading. Chemistries are visually indistinguishable. And dangerous lithium-ion cells are increasingly found in mixed waste streams where they don’t belong.

Optical systems and manual handling rely on surface characteristics, which makes them unreliable for damaged, unlabeled, or counterfeit batteries. The result is cross-contamination, regulatory violations, or even fires.

A New Approach: X-ray Vision Meets Machine Learning

Since 2018, LINEV Systems has pioneered a fundamentally different solution—BATTERAY. Instead of relying on labels or physical appearance, BATTERAY ZETA analyzes internal structures and material densities using safe, low-dose X-ray imaging. AI algorithms interpret these signatures to sort batteries by chemistry with exceptional precision.

This method enables classification even when markings are erased, form factors are non-standard, or batteries are severely corroded. From alkaline to lithium-ion, from NiCd to NiMH—BATTERAY ZETA brings true visibility to every cell that enters the system.

Platform Architecture: ZETA, ZETA-Ni, and ZETA-Li

The BATTERAY ZETA ecosystem is built as a modular platform to adapt to evolving recycling challenges. Three configurations support different market needs:

• ZETA: Base system for 6-group classification including zinc-carbon, alkaline, NiMH, NiCd, lithium primary, and lithium-ion cells.
• ZETA-Ni: Enhanced classification with dedicated separation of NiCd and NiMH cells for compliance with EU Regulation 2023/1542.
• ZETA-Li: Advanced lithium configuration supporting detection and sorting of lithium-ion subtypes (NMC, LFP, LCO, NCA).

Each configuration can operate as a standalone system or be upgraded via software and hardware modules, ensuring investment continuity and scalability.

How It Works: Multi-Stage Sorting Pipeline

BATTERAY ZETA processes batteries through a staged architecture:

1. Debris Filtering: Small debris, dust, and broken battery pieces are automatically separated to protect system integrity.
2. Alignment Conveyor: Batteries are positioned uniformly for optimal X-ray exposure and processing consistency.
3. X-ray Analysis: Internal structure and density maps are captured for each cell in real time.
4. AI Classification: A trained neural network matches each X-ray signature to a specific chemistry group.
5. Pneumatic Sorting: Identified batteries are directed into collection bins; unknowns are discharged for manual review.

X-ray + Optical + AI = Multi-Sensor Intelligence

BATTERAY ZETA enhances core X-ray capabilities with optical recognition and AI ensemble models. This fusion enables:

• Detection of physical damage, corrosion, or missing casings
• Supplemental sorting for shape or size-based filtering
• Confidence scoring and fallback strategies for ambiguous cells

Built for Industrial Demands

With a conveyor speed of 1.0 m/s and real-time classification capabilities, BATTERAY ZETA handles over 18,000 batteries per hour—up to 430 kg. The enclosed system ensures operator safety and includes automatic reject handling for unclassified or suspect batteries.

Why It Matters

As regulations tighten and the volume of hazardous battery waste rises, recyclers and e-waste processors need tools that deliver real compliance—not just throughput. BATTERAY ZETA enables that transition by achieving:

• 99.5% purity for alkaline and zinc-carbon batteries
• 95%+ purity for lithium, NiMH, and NiCd cells
• Complete autonomy with minimal operator intervention

It’s not just battery sorting. It’s a platform for safer recycling, cleaner recovery streams, and full traceability—from bin to refinery.