The global rise in battery-powered devices is fueling a parallel crisis: the growing volume of discarded portable batteries. For recycling facilities, waste management companies, and e-waste processors, this creates serious operational challenges that go beyond logistics.
Portable batteries contain hazardous materials. If they are improperly identified or sorted, they can contaminate recycling streams, damage processing equipment, or ignite fires. According to industry data, lithium battery fires alone cause more than $1.2 billion in damage to the recycling sector every year [source].
Low sorting accuracy leads to costly disruptions: contamination of valuable fractions, shutdowns, regulatory penalties, and lost client trust. Manual sorting is no longer a sustainable option—it’s time-consuming, error-prone, and unsafe in high-volume environments.
If you’re facing similar issues, you’re in the right place. Our technology is built to solve exactly these challenges—with precision, safety, and speed. Keep reading to discover how it works, or click the button below to learn more on our product site.
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Datasheet
Since 2018, our team of engineers and imaging scientists has been working to solve one of the most complex challenges in battery recycling—reliable identification and sorting of waste batteries. That’s how BATTERAY was born: an advanced X-ray battery sorting system built for speed, safety, and chemical accuracy.
Unlike traditional optical methods or manual sorting, BATTERAY analyzes the internal structure of each battery using safe, low-dose X-ray technology—classifying them by chemistry, regardless of external labeling, color, or wear. This eliminates misidentification risks and enables precise classification of mixed streams of Li-ion, Alkaline, NiMH, and more.
Key Advantages
- BATTERAY is a patented, AI-powered technology with no equivalent on the market.
- The system identifies battery types even when labels are damaged, missing, or counterfeit.
- Internal structure, not surface features, is used for classification—ensuring unmatched purity of sorting.
- Designed for industrial use with operator-safe X-ray exposure and streamlined workflow.
One of BATTERAY’s core innovations is its ability to visually interpret internal battery structure using high-precision X-ray imaging. This allows the system to identify battery chemistry with a high level of confidence, even for unmarked, damaged, or previously unseen batteries—significantly reducing sorting errors and safety risks.
Powered by adaptive machine learning, BATTERAY continuously improves as it works. Operators can add unknown battery types to the internal database, helping the system evolve and maintain maximum performance across growing battery streams. With productivity of up to 18,000 batteries per hour and sorting purity up to 99.5%, it delivers industrial-grade performance in real-world environments.
The system features a user-friendly interface, modular hardware layout, and customizable software protocols, making it easy to integrate into existing workflows. Its flexible architecture supports a wide range of battery formats—from AAAA and CR2 to large cylindrical cells like 18650 and 21700.
Smart Software Capabilities
- Default sorting using a built-in classification map
- Extended sorting with user-added battery types and chemistries
- Custom classification for rare or non-standard sizes outside the pretrained map
Supported battery groups:
- Zinc–Carbon (ZnC)
- Alkaline (Alk)
- Lithium-Ion (Li-ion)
- Lithium Primary (Li-Primary): Li-SOCl₂, Li-MnO₂, Li-FeS₂
- Nickel-Cadmium (NiCd)
- Nickel-Metal Hydride (NiMH)
- Mixed NiCd/NiMH group
Sort map
| ZN | ALK | NiCd/MH | NiCd | NiMH | Primary Li | Li-Ion | |
| AAAA | + | + | + | + | + | ||
| AAA | + | + | + | + | + | + | + |
| AA | + | + | + | + | + | + | + |
| C | + | + | + | + | |||
| D | + | + | + | + | + | + | |
| 6F22 (9V) | + | + | + | + | |||
| 21700 | + | ||||||
| 18650 | + | ||||||
| A23 | + | ||||||
| A27 | + | ||||||
| CR2 | |||||||
| 16340 (R123) | + | + | |||||
| 1/2 АА | + |
Key features 
Damaged Batteries Detection
BATTERAY accurately detects damaged, corroded, or counterfeit batteries by analyzing their internal structure. It identifies battery types even when external labels are missing, damaged, or misleading.
AI-Powered X-Ray Sorting
The system combines X-ray imaging with machine learning algorithms to classify batteries by their internal chemistry. This enables real-time, autonomous, and highly precise sorting across a wide range of battery types.
Industrial-Grade Productivity
BATTERAY is built for high-throughput operations, capable of sorting up to 350 kg of batteries per hour — or approximately 18,000 units per hour — ensuring continuous, efficient processing in demanding environments.
High Purity of Sorting
The system delivers exceptional classification accuracy, achieving up to 99.5% purity for Alkaline and Zinc–Carbon batteries, and over 95% for Lithium, NiMH, NiCd, and mixed chemistries.
Extensive Battery Compatibility
BATTERAY supports a wide variety of consumer and industrial battery types and formats — including AAAA, AAA, AA, C, D, 6F22 (9V), A23, A27, CR2, 18650, 21700, and more.
Patented and Proven Technology
Developed and manufactured by LINEV Systems, BATTERAY is protected by international patents. It is a unique solution in the global market — unmatched in its ability to combine safety, precision, and automation in battery sorting.
Damaged Batteries Detection
BATTERAY accurately detects damaged, corroded, or counterfeit batteries by analyzing their internal structure. It identifies battery types even when external labels are missing, damaged, or misleading.
AI-Powered X-Ray Sorting
The system combines X-ray imaging with machine learning algorithms to classify batteries by their internal chemistry. This enables real-time, autonomous, and highly precise sorting across a wide range of battery types.
Industrial-Grade Productivity
BATTERAY is built for high-throughput operations, capable of sorting up to 350 kg of batteries per hour — or approximately 18,000 units per hour — ensuring continuous, efficient processing in demanding environments.
High Purity of Sorting
The system delivers exceptional classification accuracy, achieving up to 99.5% purity for Alkaline and Zinc–Carbon batteries, and over 95% for Lithium, NiMH, NiCd, and mixed chemistries.
Extensive Battery Compatibility
BATTERAY supports a wide variety of consumer and industrial battery types and formats — including AAAA, AAA, AA, C, D, 6F22 (9V), A23, A27, CR2, 18650, 21700, and more.
Patented and Proven Technology
Developed and manufactured by LINEV Systems, BATTERAY is protected by international patents. It is a unique solution in the global market — unmatched in its ability to combine safety, precision, and automation in battery sorting.
After the operator loads the portable battery sorting machine, batteries move through the initial separation conveyor, which filters out small debris, dust, broken parts, and miniature batteries. This protects system components and improves purity of sorting.
Batteries then pass through the X-ray inspection system, where internal structures are analyzed in real time. Our patented AI battery recognition software identifies battery chemistry — even if the external labeling is missing, damaged, or counterfeit.
Identified batteries are routed by pneumatic injectors into designated bins based on chemistry — such as Li-ion, Alkaline, NiMH, or Lithium Primary. The system achieves up to 99.5% sorting purity for common types and maintains throughput of up to 18,000 batteries/hour.
Batteries that cannot be automatically classified — due to unusual structure or missing profiles — are redirected to a separate container for additional scanning or manual quality control. This ensures compliance and minimizes sorting errors.
Engineered for industrial efficiency, BATTERAY’s conveyor system maintains a consistent flow at 1.0 m/s—supporting uninterrupted sorting at rates exceeding 350 kg per hour.
With 99.5% purity for Alkaline and Zinc–Carbon batteries, the system delivers the level of precision required by professional recycling facilities—minimizing cross-contamination and rework.
BATTERAY comes preloaded with a wide classification map covering the most common battery types and sizes on the market. The database is continuously expandable using AI, adapting to new formats and chemistries over time.
Product Videos
Technical data
X-ray source
| X-ray emission | Complies with the standard: 1 μSv/h at any point at a distance of 10 cm from the device. Typical value of our system less than 0.3 μSv |
| X-ray protection | Full operator protection |
Loading
| Loading hopper capacity, up to | 350 kg |
| Loading hopper volume | 250 L |
| Conveyor speed | 1.0 m/s |
| Productivity of pure fractions | up to 18000 batteries/hour |
| Pneumatic | 10 bar ±10%, ≥500 SLPM |
| Throughput capacity | 350 kg/hour |
Dimensions
| Overall dimensions (maximum) | ||
|---|---|---|
| Lenght | 7960 mm | |
| Width | 2690 mm | |
| Height | 2400 mm |
| Layout | 15000 x 8000 mm |
|---|
| Weight (maximum) | 2400 kg |
|---|
Purity
| Zinc-carbon, alkaline | 99,5 % |
| All groups | >95 % |
X-ray source
| X-ray emission | Complies with the standard: 0.1 mrem/h at any point at a distance of 4 in from the device. Typical value of our system less than 0.03 mrem |
| X-ray protection | Full operator protection |
Loading
| Loading hopper capacity, up to | 772 lbs |
| Loading hopper volume | 66 gal |
| Conveyor speed | 3.28 ft/s |
| Productivity of pure fractions | up to 18,000 batteries/hour |
| Pneumatic | 145 psi ±10%, ≥17.7 SCFM |
| Throughput capacity | 772 lbs/hour |
Dimensions
| Overall dimensions (maximum) | ||
|---|---|---|
| Length | 26.1 ft | |
| Width | 8.82 ft | |
| Height | 7.87 ft |
| Layout | 49.2 x 26.2 ft |
|---|
| Weight (maximum) | 5,291 lbs |
|---|
Purity
| Zinc-carbon, alkaline | 99.5 % |
| All groups | >95 % |
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Customer Reviews & Installation Videos
Today’s waste stream includes over 200 types of batteries and accumulators, varying in shape, size, and chemical composition. Many of them fall into the category of hazardous household waste, containing toxic heavy metals like mercury, cadmium, and lead. In fact, spent batteries are responsible for up to 40% of all pollutants entering the environment through household trash.
Effectively sorting this wide spectrum of batteries is a serious challenge—especially when external labels are missing or misleading. Traditional optical and manual sorting methods, although widely used, are inherently limited: they rely on surface characteristics rather than internal structure, making them prone to misclassification and safety risks.
That’s where BATTERAY comes in. Since 2018, LINEV Systems has been developing a fundamentally different approach—using safe, low-dose X-ray technology combined with machine learning. This technology allows for accurate identification of battery chemistry based on internal features, not external appearance. It overcomes the key limitations of legacy systems and provides the precision needed for high-purity, high-speed industrial sorting.
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