Automated Sorting and Filtration in Recycling Plants

In recycling plants, proper separation and filtration of waste are crucial for both environmental sustainability and economic efficiency. Automated sorting systems minimize human error while providing high processing speeds.

Scenario: Mixed Plastic and Paper Line

A mid‑size recycling facility located in western Istanbul processes 1,200 tons of waste daily. About 45 % of the waste is plastic, 35 % paper, and the remaining 20 % consists of metal and organic residues. The mixed waste first passes through a pre‑screening conveyor where large metal pieces are removed by an electromagnetic separator.

The plastic‑paper mixture is then sent to an optical sensor sorting station developed by Botex System. The sensors analyze color, density, and reflectance in real time. Plastics are diverted to a separate conveyor by high‑frequency air jets, while paper is pulled by low‑pressure vacuum.

Filtration and Quality Control

After sorting, both streams enter dedicated filtration units. The plastic stream passes through 0.5 mm perforated metal filters that capture fine dust and residues; the paper stream is treated with electrostatic collectors that gather fine fibers. This stage ensures the final product meets quality standards.

Filtrate water is routed to a biological treatment tank, minimizing harmful emissions. The entire process is monitored by a PLC‑based control unit that cycles every 5 seconds and triggers alarms on any anomaly.

Energy Efficiency and Data Analytics

The automated line uses regenerative drives and frequency converters to cut energy consumption by 30 %. Each sensor and actuator streams data to an IoT platform; the cloud‑based analytics engine processes this data to predict maintenance needs.

Operators monitor KPIs such as processing speed, sorting efficiency, and filter life via a SCADA interface, enabling planned maintenance and preventing unexpected downtime.