As portable battery volumes grow, manual sorting has become a limiting factor for safe and scalable recycling. The article describes five challenges facing recycling operators: labour inefficiencies, scaling barriers for small and medium facilities, fire and handling safety risks from lithium-ion and damaged batteries, difficulty securing affordable insurance, and rudimentary alternatives that miss chemistries and form factors. To address these issues, researchers at VITO and operational experts at Sortbat have developed a new solution that is now being scaled globally through Smiths Detection. The system is positioned as a step change in technology for batteries up to 5 kg and is described as ready for industrial deployment.
The core technology is a multi-sensor detection platform powered by machine learning. It combines X-ray, optical and laser sensors to characterise and sort mixed portable battery streams, delivering reported accuracy above 98 percent across chemistries and formats, including packs up to 5 kg. Throughput is cited at up to 2.4 tons per hour, or roughly 4–5 kilotonnes annually, which the article contrasts with typical legacy rates below 0.5 ton per hour. The solution is modular and covers the full workflow from pre-sort, sieve and feed to characterisation, sorting and safety. Optional features include a fire safety module and upgradable software, and the platform provides real-time reporting for operational transparency and regulatory compliance.
The system is already running daily at Sortbat facilities, which the article presents as evidence of industrial viability and sustained reliability rather than a pilot-stage concept. Customer benefits listed include maximised throughput, reduced labour costs, improved safety and handling, simplified insurance processes through built-in risk reduction, competitive advantage, and support for circular economy objectives. The article ends by inviting readers to learn more at the International Congress for Battery Sorting on 10 September and to book private meetings on 10 or 11 September via the provided scheduling link.
