LIBS, XRT, XRF, and NIR sorters are considered high-end solutions for modern recycling technology among recyclers. They offer the highest accuracy in identifying recyclable materials, fully automated sorting of materials, and maximum recovery of recyclable materials—and today, this is often achieved with AI-powered recognition.
However, for these intelligent sorters to operate both precisely and with high efficiency, the input material must be properly prepared.
A key factor for success here is precise screening process according to defined particle size ranges—that is, pre-sorting the material based solely on size.
This is because LIBS, NIR, XRF, or XRT sorting systems can only reach their full potential if the particle sizes are precisely maintained and the material no longer contains any contaminants (e.g., fine particles or long pieces).
In this post, we’ll show you:
• Why Good screening technology is the right partner for modern sorting equipment
• What to consider regarding the screening process when designing a recycling plant’s process line
• And how you can significantly increase the sorting performance and profitability of your entire plant through optimal classification screening
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Why the Precise Screening Process Is So Important for Your Sorting Plant
Not all trash is the same
Whether it’s LIBS sorting technology, NIR sorting, or X-ray sorting technology (such as XRF and XRT)—all sensor-based sorting machines perform best when the input material is neatly sorted by size.
To do this, it is necessary to pre-screen fine material (which is usually heavily contaminated) beforehand. In practice, screening sizes such as 0–10, 0–15, or—depending on the recycling goal—even 0–20 mm are suitable for this purpose. This reliably keeps the very fine material—which could simply contaminate or even damage the sorting equipment (e.g., by becoming lodged under the conveyor belts)—away from the sensitive sorting technology. In addition, the fine fraction can interfere with and hinder the sorting equipment’s ability to correctly identify and detect the material.
In addition, the additional screening sizes—such as 10–30 mm or 20–60 mm—produce the ideal particle size distribution for the sorting machines. The sorting machines operate optimally with a particle size distribution ratio of 1 to 3.
The screening machine is also used to remove long pieces. This has the advantage that the material to be detected is not obscured or covered by larger pieces. In addition, screening the long parts prevents them from standing upright unintentionally—for example, on the conveyor belt of the sorting machine—due to the belt’s speed. This reduces the risk of damage to the expensive equipment mounted above the conveyor belt. In addition, due to their physical properties, long pieces often fly into the target fraction like a javelin throw or unintentionally drag smaller pieces along with them.
The goal of the screening process is to remove disruptive material—whether fine or coarse, moist, or sticky—and thereby optimize sorting accuracy. In addition, high-quality screening machines ensure that the material is evenly distributed across the entire working width of the sorting machine.
What happens if the screening results are inaccurate?
- In practice, incorrect and imprecise screening sizes lead to costly losses of recyclable materials
- The target fractions can easily become contaminated, which leads to lower sales revenue
- This results in time-consuming re-sorting and, consequently, duplicate work
- The sorting equipment is exposed to an unnecessary risk of damage
- Production costs per metric ton are rising, while yields are falling
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Technical Background – Explained Simply
Example of LIBS Sorting (Laser-Induced Breakdown Spectroscopy):
In order to precisely detect aluminum-containing metal alloys using the relatively new LIBS technology, each individual piece of material must be fed into the LIBS sorting device in an optimally positioned manner. It is also beneficial if the material is free of dirt and debris (keyword: screening out unwanted fine particles).
Example: NIR:
Moist, sticky Biomass or contaminated Plastic waste with fine particles adhering to it that have not been screened out can cause false signals during NIR detection.
Conclusion: The more consistent the particle size distribution after the screening process, the better the sorting results. That is why we at SPALECK consistently stand behind our BEST SCREENING philosophy. BEST SORTING. FOR THE BEST SORTING QUALITY.
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4 Common Mistakes—and How to Avoid Them
Error
- Inadequate fractionation before the sorting equipment
- Material that is too dirty, wet, or sticky is fed into the sorting machines
- irregular material feed
- Blockages in the screening panels
Risk
- Poor material yield, sloppy processes
- Damage to the sorting equipment, sorting errors
- Overloading or Underloading the Sorter
- Extensive cleaning required, poor grain distribution on the conveyor belt for the sorter
Solution Using SPALECK Technology
- Highly precise screening process with 2–5 fractions, depending on the type of screening machine
- Screening panels selected specifically for each type of recyclable material to produce very precise fractions
- Screening machines that deliver the material perfectly, or alternatively, ActiveFEED technology for continuous feeding
- SPALECK ModularDESIGN+ with Quick-Change System
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The optimal solution: FOR BEST SORTING QUALITY
Our SPALECK screening technology is 100 percent tailored to your Recycling process. This ensures optimal results in the downstream magnetic and sensor sorting processes.
Among other things, the following are used:
- 3D COMBI Screening Machines
A high-performance double-deck screening machine with up to 5 fractions.
- Tension-Shaft Screening Machines
Equipped with innovative tensioned-shaft screening technology—for example, our MultiZONE DECK, which enables varying material accelerations for an optimal screening and feeding process.
- Recycling Waste Screens
We also build our Recycling Waste Screens specifically for your application. Like all SPALECK screening machines, they are modular and can be optimally adapted even when switching materials.
- ActiveFEED infeed unit
ActiveFEED technology stands for NEXT LEVEL SORTING —as confirmed by customers and sorting equipment manufacturers.
- Optional:
Special features for process optimization tailored to your recycling material.
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What are the specific benefits for you?
Benefits for Your Recycling Business:
- Higher Sorting Quality: Top-Quality Recycled Material for Optimal Recovery
- Less re-sorting: Time savings, optimized staffing needs
- Higher material yield: More yield per metric ton, less waste
- More Efficient Line Operations: Increasing System Availability, Protecting the Equipment in Use
- Faster Payback on Sorters: Higher Output with the Same Technology = Increased Return on Investment
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Project Examples: Metal Recycling and Waste Wood Processing
Example: Non-ferrous Metal Recycling
• The use of a SPALECK 3D COMBI screening machine enables virtually maintenance-free operation with excellent screening and sorting results
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Example: Waste Wood Processing
• The use of a SPALECK Recycling Waste Screen in waste wood processing ensures precise screening sizes for subsequent metal separation and thermal recycling
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Expert Knowledge at a Glance
“The economic outcome of any Recycling process depends on the interaction of the technologies used. If I use the wrong technology in the process—or if it isn’t optimally suited to my material—the overall result suffers. When it comes to screening technology, we take great care to ensure that the screening process is a key factor in the success of your recycling process.”
Frederik Stening, Head of Application Engineering at SPALECK
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Test Your Sorting Line for Performance
Book comprehensive testing of your material at the SPALECK TestCenter now—free of charge, of course!
After a day of joint testing at the SPALECK TestCenter, you’ll know how to get the most out of your material.
