As the world accelerates towards decarbonisation and resource efficiency, the safe and effective collection, sorting and recycling of portable batteries has become a critical priority. Yet, traditional manual sorting methods, labour-intensive, error-prone, and increasingly challenging for workers to handle, can no longer keep pace with rising volumes and complex battery streams.
What’s needed is a step change in technology
That breakthrough is here for all batteries up to 5kg: an AI-powered, multi-sensor sorting system, developed through years of research at VITO and operational, daily sorting expertise at Sortbat, now scaled globally through Smiths Detection. This fully integrated, end-to-end solution is proving its reliability and readiness for industrial deployment.
Why change is needed
Recycling operators today face five major challenges:
- Labour inefficiencies – Manual sorting is slow, costly, and heavily dependent on scarce skilled labour.
- Scaling barriers – Small and medium-sized facilities often hit a growth ceiling without automation.
- Safety risks – Lithium-ion and damaged batteries introduce significant fire hazards.
- Insurance hurdles – High perceived risks make affordable insurance difficult, threatening business continuity.
- Inferior alternatives - Other systems on the market attempt to do the job, but they are rudimentary. They don’t capture all chemistries and form factors, and they lack the accuracy needed to deliver reliably sorted outputs
The new system directly addresses each of these issues, transforming bottlenecks into opportunities for growth, compliance, and safety.
The Technology: AI Meets Multi-Sensor Precision
At the heart of the solution is a multi-sensor detection platform, powered by machine learning and built to handle the complexity of mixed portable battery streams.
Key Capabilities:
- Superior Detection – Combines X-ray, optical, and laser sensors for >98% accuracy across chemistries and formats, including packs up to 5 kg.
- Industry-Leading Throughput – Can process up to 2.4 tons per hour (4–5 kt annually), far surpassing traditional alternatives (typically <0.5 t/h).
- End-to-End Workflow – Fully modular, covering pre-sort, sieve, feed, characterisation, sorting, and safety, reducing the need for multiple systems.
- Safety Built-In – Optional fire safety module designed to reduce operational risks and potentially lower insurance premiums.
- Future-Proof Scalability – Modular hardware and upgradable software ensure the system grows with your business.
- Data-Driven Insights – Real-time reporting for operational transparency and regulatory compliance.
Proven in the Real World
Unlike many concepts still in pilot, this solution has been developed and implemented for years and is now fully running daily at Sortbat facilities, demonstrating industrial viability and sustained reliability. With a proven track record, it offers recyclers confidence in safety, performance, scalability, and ROI.
Customer Benefits at a Glance
- Maximised throughput, reduced costs – Automated accuracy and speed cut down labour costs and increase profitability.
- Enhanced safety – Mitigate fire and handling risks, protecting both people and facilities.
- Simplified insurance processes – Built-in risk reduction may improve coverage options and lower premiums.
- Competitive advantage – Outperform peers with higher throughput, better detection, and lower cost per unit.
- Circular economy leadership – Meet sustainability, compliance, and policy demands while building resilience into your operations.
Driving the Circular Economy Forward
By combining AI intelligence, multi-sensor precision, and industrial scalability, this solution represents more than just automation, it is a catalyst for the circular economy. It enables recyclers, logistics operators, electronics firms, and policymakers alike to close the loop on portable batteries while unlocking new economic value. More importantly, it lays the foundation for a safer, more sustainable, and economically viable future, where resource recovery keeps pace with global demand and the circular economy can finally scale.
Find out More at this year’s International Congress for Battery Sorting (ICBR)
Join our session on 10 September - Session 2b: innovative approaches in battery recycling
Book a private meeting with us on 10 or 11 September - https://calendly.com/events-smithsdetection/icbr-exclusive-one-to-one.