The volume of waste portable batteries is growing every year, and recycling operators are under increasing pressure to process mixed battery streams safely, accurately, and efficiently.
Portable batteries are hazardous waste. They may contain toxic metals, reactive lithium chemistries, damaged cells, counterfeit products, and batteries with missing or unreadable labels. If they are not correctly identified and separated, they can contaminate valuable fractions and increase operational risk.
Battery fires remain one of the most serious challenges for waste and recycling facilities. According to Waste360, “the cost of fires to the waste and recycling operators and to the fire professionals who are forced to fight these fires is more than US$1.2 billion annually” waste360.com.
This is why reliable battery chemistry identification matters. BATTERAY Series technology uses X-ray analysis, AI-powered recognition, and, in advanced platforms, combined optical and X-ray detection to reveal the true chemistry inside every battery and support cleaner, safer recycling operations.
Read more from linevsystems.com
Datasheet
Since 2018, LINEV Systems has been developing X-ray battery sorting technology to solve one of the most difficult challenges in battery recycling: identifying the true chemistry of mixed waste batteries when labels are missing, damaged, corroded, or unreliable.
BATTERAY is an industrial X-ray battery sorting machine designed to identify portable waste batteries by internal composition and sort them into clean fractions for downstream recycling. It is the proven and most cost-efficient platform within the BATTERAY Series.
Key Factors
- BATTERAY uses X-ray battery inspection to identify chemistry by internal structure, not by external markings.
- The system recognizes unmarked, corroded, and counterfeit batteries where optical or manual sorting may fail.
- BATTERAY supports AI-powered battery sorting with a supervised self-learning database that can be expanded over time.
- The BATTERAY Series also includes BATTERAY ZETA and BATTERAY ZETA PRO for higher throughput, optical + X-ray recognition, and greater automation.
The core advantage of BATTERAY technology is its ability to analyze the internal structure of each battery using X-ray imaging. This allows the system to classify batteries by chemistry even when the outside shell is damaged, dirty, corroded, or deliberately misleading.
Machine-learning algorithms support semi-automatic expansion of the battery database, helping system owners reduce the share of unrecognized batteries as new formats, brands, and battery types appear in the recycling stream.
BATTERAY is designed for industrial recycling operations that require reliable battery chemistry identification without unnecessary complexity. It provides a practical entry point into automated battery sorting and is widely used in recycling plants across Europe, North America, and Australia.
BATTERAY Series
BATTERAY is the proven platform of the BATTERAY Series — a family of industrial battery sorting systems that also includes the advanced BATTERAY ZETA and the high-capacity BATTERAY ZETA PRO platforms. Each system is based on the same core X-ray chemistry recognition technology while offering different levels of throughput, automation, and plant integration.
Software Features
- Standard sorting using the default battery sort map
- Sorting with customer-added batteries (default sort map + customer base)
- Custom programs for adding previously unrecognized batteries to the database
- Support for battery sizes from AAAA to 21700 and other cylindrical formats
Sorting battery groups:
- Zinc–Carbon (ZnC)
- Alkaline (Alk)
- Lithium-Ion (Li-Ion)
- Lithium Primary
- Lithium Iron Disulfide (Li-FeS2)
- Lithium Manganese Dioxide (Li-MnO2)
- Lithium Thionyl Chloride (Li-SOCl2)
- Nickel-Cadmium (NiCd)
- Nickel-Metal Hydride (NiMH)
- Mixed NiCd/NiMH group
Sort map
| ZnC | Alk | NiCd / NiMH | NiCd | NiMH | Li-Primary* | Li-Ion | |
| AAAA (LR61) | + | + | + | + | + | ||
| AAA (R03) | + | + | + | + | + | + | + |
| AA (LR6) | + | + | + | + | + | + | + |
| C (LR14) | + | + | + | + | |||
| D (LR20) | + | + | + | + | + | + | |
| 6F22 (9V) | + | + | + | + | |||
| 21700 | + | ||||||
| 18650 | + | ||||||
| A23 | + | ||||||
| A27 | + | ||||||
| CR2 | + | ||||||
| 16340 (CR123) | + | + | |||||
| 14250 (1/2 AA) | + |
* Li-Primary group includes Li-SOCl2, Li-MnO2 and Li-FeS2 battery chemistries.
Key features
Unmarked Battery Detection
Identifies unmarked, corroded, and counterfeit batteries by analyzing internal structure instead of relying on labels, color, or external condition.
AI-Powered X-Ray Recognition
Uses X-ray battery inspection and machine-learning algorithms to classify battery chemistry with high reliability in mixed waste battery streams.
Industrial Productivity
Supports automated battery sorting with throughput up to 350 kg per hour, depending on the input material and battery mix.
High purity of sorting
Achieves 99.5% sorting purity for Alkaline and Zinc-Carbon batteries, and over 95% for other supported battery groups.
Popular types of batteries
Includes a comprehensive sort map covering the most common portable battery types and sizes, from AAAA and 9V to 18650 and 21700 formats.
Proven BATTERAY Technology
Patented LINEV Systems technology, developed for industrial recyclers that need reliable X-ray battery sorting, cleaner output fractions, and reduced manual handling.
Unmarked Battery Detection
Identifies unmarked, corroded, and counterfeit batteries by analyzing internal structure instead of relying on labels, color, or external condition.
AI-Powered X-Ray Recognition
Uses X-ray battery inspection and machine-learning algorithms to classify battery chemistry with high reliability in mixed waste battery streams.
Industrial Productivity
Supports automated battery sorting with throughput up to 350 kg per hour, depending on the input material and battery mix.
High purity of sorting
Achieves 99.5% sorting purity for Alkaline and Zinc-Carbon batteries, and over 95% for other supported battery groups.
Popular types of batteries
Includes a comprehensive sort map covering the most common portable battery types and sizes, from AAAA and 9V to 18650 and 21700 formats.
Proven BATTERAY Technology
Patented LINEV Systems technology, developed for industrial recyclers that need reliable X-ray battery sorting, cleaner output fractions, and reduced manual handling.
BATTERAY Series: for Every Recycling Scale
The BATTERAY Series was developed to help recyclers choose the right level of automation, throughput, and plant integration for their battery sorting operation. Each platform is based on the same core idea: identifying battery chemistry by looking inside the battery, not relying only on labels, color, or external condition.
From reliable X-ray battery sorting for standard recycling workflows to advanced multi-sensor recognition and fully automated industrial-scale processing, the series allows operators to move from proven battery chemistry identification to a higher level of productivity and process control.
BATTERAY
|
BATTERAY ZETA
|
BATTERAY ZETA PRO
|
Want to learn more about the advanced BATTERAY ZETA and BATTERAY ZETA PRO platforms? Visit batterayzeta.com for a deeper overview of the series evolution, platform differences, and industrial applications.
The conveyor system supports continuous industrial battery sorting with throughput up to 350 kg per hour, depending on battery mix and input conditions.
Sorting purity for Alkaline and Zinc-Carbon batteries reaches up to 99.5%, while other battery groups achieve purity levels above 95%, meeting the requirements of modern recycling facilities.
The system includes a comprehensive battery recognition database covering the most common portable battery types and sizes, allowing recyclers to process mixed waste battery streams more efficiently.
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 18,000 batteries/hour |
| Pneumatic | 10 bar ±10%, ≥500 SLPM |
| Throughput capacity | up to 350 kg/hour, material-dependent |
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/h |
| X-ray protection | Full operator protection |
Loading
| Loading hopper capacity, up to | 772 lb |
| 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 | up to 772 lb/hour, material-dependent |
Dimensions
| Overall dimensions (maximum) | ||
|---|---|---|
| Length | 26.1 ft | |
| Width | 8.8 ft | |
| Height | 7.9 ft |
| Layout | 49.2 x 26.2 ft |
|---|
| Weight (maximum) | 5,291 lb |
|---|
Purity
| Zinc-carbon, alkaline | 99.5 % |
| All groups | >95 % |
Feedbacks and related links
Customer Reviews & Installation Videos
Modern battery recycling starts with a difficult technical question: how can a mixed stream of portable batteries be classified accurately when many items are corroded, damaged, unmarked, counterfeit, or visually similar? With more than 200 battery types and formats on the market, surface-based identification alone is not reliable enough for industrial battery sorting.
Traditional methods such as manual inspection, optical recognition, weight-based sorting, and magnetic separation can support parts of the process, but each has limitations. Labels may be missing or misleading, battery casings may be damaged, and batteries with similar size or shape may have different internal chemistries.
X-ray battery inspection solves this problem by analyzing the internal structure of the battery rather than its external appearance. The system evaluates internal features, material density, absorption patterns, and structural characteristics that are directly connected to battery chemistry.
Since 2018, LINEV Systems has been developing this approach into industrial battery sorting technology. BATTERAY uses X-ray recognition and AI-supported classification to identify battery chemistry, improve sorting purity, and help recyclers obtain cleaner fractions for downstream processing.
Event сalendar
The fastest way to hear back from us is completing the contact form below. Our expert team will get back to you as soon as possible.