The growth of portable battery waste has created a new technical challenge for recycling facilities: mixed battery streams must be processed faster, more safely, and with a much higher level of chemistry recognition than traditional sorting methods can provide.
BATTERAY ZETA Series was developed as a family of three battery sorting systems for different levels of recycling operations: BATTERAY, BATTERAY ZETA, and BATTERAY ZETA PRO. All three are designed to solve the same core problem — accurate battery chemistry identification in mixed waste streams — but each platform offers a different level of throughput, automation, and plant integration.
The proven BATTERAY system provides X-ray battery sorting for reliable chemistry recognition. BATTERAY ZETA adds multi-sensor recognition by combining optical analysis, X-ray inspection, and machine-learning algorithms. BATTERAY ZETA PRO extends the concept into a high-capacity automated platform for large recycling plants.
Together, the series helps recycling operators move from uncertain visual sorting to structured battery sorting technology: cleaner fractions, improved recognition of complex mixed streams, reduced contamination risk, and a platform architecture prepared for future Li-ion sub-classification development.
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Datasheet
BATTERAY ZETA Series is a multi-sensor battery sorting platform developed for recycling facilities that need more than basic visual identification. The series combines X-ray battery inspection, optical analysis, and machine-learning algorithms to identify battery chemistry in mixed waste streams.
The platform is built as a three-level technology family: BATTERAY, BATTERAY ZETA, and BATTERAY ZETA PRO. Each system solves the same core task — reliable battery chemistry recognition — but at a different level of throughput, automation, and plant integration.
Key Advantages
- Multi-sensor battery recognition combining X-ray and optical technologies
- Improved classification of unmarked, corroded, counterfeit, and visually similar batteries
- Enhanced Ni-Cd / Ni-MH separation for cleaner nickel-based fractions
- Scalable architecture from supervised sorting to high-capacity automated processing
Series Logic
| System | Core Role | Best Fit |
|---|---|---|
| BATTERAY | Proven X-ray battery sorting system | Reliable and cost-efficient chemistry identification |
| BATTERAY ZETA | Advanced optical + X-ray recognition platform | Higher throughput, improved recognition, and plant integration |
| BATTERAY ZETA PRO | High-capacity automated sorting platform | Large recycling plants and continuous industrial workflows |
Clues
- BATTERAY ZETA Series is built on the proven BATTERAY X-ray sorting foundation
- ZETA adds high-resolution optical vision, improved software, advanced statistics, and plant integration
- ZETA PRO extends the architecture for large plants with higher throughput, recirculation, and advanced monitoring
- Advanced Li-ion sub-classification is part of the R&D roadmap, while the platform architecture is designed to support future development
Overview
BATTERAY ZETA Series was created for recycling operators who need a structured way to move from basic battery sorting toward a more integrated, data-driven, and automated process. The key idea is not only to separate batteries into output groups, but to improve recognition quality, reduce manual re-sorting, and support cleaner material fractions.
The original BATTERAY system established the core X-ray battery sorting technology: the battery is identified by internal structure rather than label, color, or surface condition. BATTERAY ZETA develops this concept further by combining X-ray inspection with optical recognition, a larger software environment, advanced statistics, and integration capabilities for modern recycling plants.
This approach is especially important for nickel-based batteries. Ni-Cd and Ni-MH cells can be visually similar, but they require different downstream handling. BATTERAY ZETA introduces an enhanced Ni-based separation module to improve recognition of these chemistries and help recyclers reduce contamination in output fractions.
BATTERAY ZETA PRO is designed for facilities where battery sorting must become part of a larger automated production line. It adds high-capacity processing, multi-stream sorting, automated recirculation of unrecognized batteries, and monitoring features that support continuous industrial operation.
Platform Comparison
| Parameter | BATTERAY | BATTERAY ZETA | BATTERAY ZETA PRO |
|---|---|---|---|
| Position in series | Proven X-ray sorting system | Advanced multi-sensor inline platform | High-capacity automated platform |
| Recognition technology | X-ray detection | Optical + X-ray detection | Optical + X-ray detection |
| Automation level | Operator-assisted | Supervised system | Automated industrial architecture |
| Nominal throughput | Up to 250–300 kg/h | Up to 350–400 kg/h | Up to 1000 kg/h |
| Sorting cycle speed | Up to 18,000 batteries/hour | Up to 23,000 batteries/hour | Up to 40,000 batteries/hour |
| Sorting purity | 99.5% Alk / ZnC, 95% other groups | 99.5% Alk / ZnC, improved Ni-based separation, over 95% other groups | 99.5% Alk / ZnC, improved Ni-based separation, over 95% other groups |
| Sorting outputs | 6 sorting groups per session | Up to 9 sorting groups per session | Up to 9 sorting groups per session |
| Plant integration | Standalone operation | Integrated inline platform with Profinet support | Integrated high-capacity line platform with Profinet support |
| Recirculation | No automated recirculation loop | No automated recirculation loop | Automated recirculation loop for unrecognized batteries |
| Best application | Standard industrial battery sorting | Advanced recycling lines requiring better recognition and analytics | Large recycling plants requiring continuous high-volume sorting |
Performance values depend on the input battery mix, material condition, and selected sorting program. The ZETA technical proposal also notes throughput up to 430 kg/h as a common feature value, while the product comparison table positions BATTERAY ZETA at up to 350–400 kg/h. For website content, the 350–400 kg/h range is safer for product comparison, while “up to 430 kg/h” can be used only with a material-dependent note.
Supported battery groups
- Zinc–Carbon (ZnC)
- Alkaline (Alk)
- Nickel-Cadmium (NiCd)
- Nickel-Metal Hydride (NiMH)
- Mixed NiCd / NiMH group
- Lithium-Ion (Li-ion)
- Lithium Primary (Li-Primary)
- Lithium Thionyl Chloride (Li-SOCl₂)
- Lithium Manganese Dioxide (Li-MnO₂)
- Lithium Iron Disulfide (Li-FeS₂)
Classification Structure
Sort map
| ZnC | Alk | NiCd / NiMH | NiCd | NiMH | Li-Primary | Li-SOCl₂ | Li-MnO₂ | Li-FeS₂ | Li-Ion | |
| AAAA (LR61) | + | + | ||||||||
| AAA (R03) | + | + | + | + | + | + | + | + | + | |
| AA (LR6) | + | + | + | + | + | + | + | + | + | + |
| C (LR14) | + | + | + | + | + | + | ||||
| D (LR20) | + | + | + | + | + | + | + | + | ||
| 6F22 (9V) | + | + | + | + | + | + | ||||
| A23 | + | |||||||||
| A27 | + | |||||||||
| CR2 | + | + | + | |||||||
| 16340 (CR123) | + | + | + | + | ||||||
| 14250 (1/2 AA) | + | + | + | |||||||
| 18650 | + | |||||||||
| 21700 | + |
Advanced sub-classification of Li-ion batteries, including LMO, NMC, and LFP, is part of the ongoing R&D roadmap. The BATTERAY ZETA Series architecture is designed to support this future functionality, but current project specifications should always be confirmed with the LINEV Systems technical team.
Key features 
AI-driven classification by internal battery structure
BATTERAY ZETA uses multi-sensor X-ray imaging and machine learning to classify batteries by internal geometry and material density — eliminating dependency on external labels, markings, or shape.
Separation of Ni-Cd and Ni-MH for regulatory compliance
Generation 2 configuration enables automated high-purity classification of Ni-Cd and Ni-MH batteries, ensuring compliance with EU Regulation 2023/1542 and eliminating contamination penalties.
Lithium-ready with standalone ZETA-Li upgrade
The system supports lithium detection by default and enables full subtype classification (NMC, LFP, LCO, NCA) through ZETA-Li — a dedicated Generation 3 system for lithium-only processing.
Sorting accuracy up to 99.5% for Zn and Alk
Delivers exceptional purity for zinc and alkaline chemistries, with over 95% accuracy for lithium, Ni-MH, and Ni-Cd groups — even when batteries are corroded, unrecognized, or counterfeit.
Industrial-grade throughput with AI optimization
BATTERAY ZETA processes up to 18,000 batteries or 430 kg per hour, with continuous operation and adaptive learning to optimize performance across complex, mixed waste streams.
Modular architecture with patented design
BATTERAY ZETA is a patented, scalable platform developed by LINEV Systems. Modular upgrades and software-based sorting programs allow flexible adaptation to future battery types and recycling needs
AI-driven classification by internal battery structure
BATTERAY ZETA uses multi-sensor X-ray imaging and machine learning to classify batteries by internal geometry and material density — eliminating dependency on external labels, markings, or shape.
Separation of Ni-Cd and Ni-MH for regulatory compliance
Generation 2 configuration enables automated high-purity classification of Ni-Cd and Ni-MH batteries, ensuring compliance with EU Regulation 2023/1542 and eliminating contamination penalties.
Lithium-ready with standalone ZETA-Li upgrade
The system supports lithium detection by default and enables full subtype classification (NMC, LFP, LCO, NCA) through ZETA-Li — a dedicated Generation 3 system for lithium-only processing.
Sorting accuracy up to 99.5% for Zn and Alk
Delivers exceptional purity for zinc and alkaline chemistries, with over 95% accuracy for lithium, Ni-MH, and Ni-Cd groups — even when batteries are corroded, unrecognized, or counterfeit.
Industrial-grade throughput with AI optimization
BATTERAY ZETA processes up to 18,000 batteries or 430 kg per hour, with continuous operation and adaptive learning to optimize performance across complex, mixed waste streams.
Modular architecture with patented design
BATTERAY ZETA is a patented, scalable platform developed by LINEV Systems. Modular upgrades and software-based sorting programs allow flexible adaptation to future battery types and recycling needs
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 pass through the AI-powered detection zone, where the system uses multi-sensor X-ray imaging to scan internal geometry and composition. No labels or surface details are needed — classification is based entirely on internal structure.
Real-time machine learning algorithms process the captured data and assign each battery to one of the pre-defined groups (e.g., Alkaline, Zinc, NiCd, NiMH, Primary Li, Li-ion). Advanced configurations enable NiCd/NiMH separation or lithium subtype recognition.
Using pneumatic injectors, each identified battery is directed into the correct output bin. Misidentified or unreadable units are diverted to a separate re-check container. This step ensures high-purity fractions and eliminates contamination risks.
Conveyor speed of 1.0 m/s ensures stable, continuous sorting up to 430 kg/h — ideal for industrial-scale operations.
Built-in calibration and performance checks keep classification precise with minimal operator input.
The system performs internal calibration routines and performance checks to maintain peak accuracy. This minimizes the need for manual intervention, reduces maintenance frequency, and ensures long-term consistency in classification quality.
BATTERAY Classic
Since its introduction, the original BATTERAY system has become one of the most widely adopted automated battery classification solutions in the industry. It set the foundation for today’s ZETA platform, but continues to be actively used and sold — delivering consistent performance in real-world operations.
Powered by AI and safe X-ray imaging, BATTERAY Classic enables precise separation of household and industrial batteries by internal structure — ensuring regulatory compliance, fire safety, and high-purity material recovery.
While it does not support Ni-Cd/Ni-MH separation or lithium subtype classification, it provides an ideal solution for clients focusing on core battery groups like Alkaline, Zinc-Carbon, Li-ion, and NiMH. For many facilities, BATTERAY Classic remains the optimal balance of capability, cost-efficiency, and operational simplicity.
Core Advantages
- Trusted by recyclers worldwide — proven in daily use for 6+ years
- Accurate AI-based classification for key chemistries: Zn, Alk, NiMH, Li-ion
- Throughput up to 350 kg/h, or 18,000 units per hour
- Compatible with most standard formats: AAAA, AAA, AA, C, D, 6F22 (9 V), A23, 18650, 21700
- Integrated into existing material flow — minimal installation or retraining required
- Expandable software map to add new battery types as waste streams evolve
Technical Note
BATTERAY Classic shares core architectural elements with the BATTERAY ZETA system — including interface, conveyor logic, classification display, and output ejection logic.
Classification Capabilities
| Battery Type | Zn | Alk | NiMH | Li-ion | NiCd | Primary Li |
|---|---|---|---|---|---|---|
| AA / AAA / C / D | ✅ | ✅ | ✅ | ✅ | ❌ | ✅ |
| 18650 / 21700 | ❌ | ❌ | ✅ | ✅ | ❌ | ❌ |
| 6F22 (9 V) | ✅ | ✅ | ✅ | ❌ | ❌ | ✅ |
*Full NiCd/NiMH separation and lithium subtype detection (NMC, LFP, LCO, etc.) are only available with BATTERAY ZETA and ZETA-Li.*
Most BATTERAY video demos and customer installations featured on our site, YouTube, and event materials showcase the Classic system. Its reliability, speed, and simplicity continue to make it the go-to choice for first-time adopters or facilities focused on core compliance.
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 | 430 kg/hour |
Dimensions
| Overall dimensions (maximum) | ||
|---|---|---|
| Lenght | 8960mm | |
| Width | 2690 mm | |
| Height | 2400 mm |
| Layout | 15000 x 8000 mm |
|---|
| Weight (maximum) | 2500 kg |
|---|
Purity
| Zinc-carbon, alkaline | 99,5 % |
| All groups | >95 % |
X-ray source
| X-ray emission | Complies with the standard: 1 μSv/h at any point at a distance of 4 in from the device. Typical value of our system less than 0.3 μSv/h |
| X-ray protection | Full operator protection |
Loading
| Loading hopper capacity, up to | 772 lbs |
| Loading hopper volume | 66 gal (US) |
| Conveyor speed | 3.3 ft/s (≈7.4 mph) |
| Productivity of pure fractions | up to 18,000 batteries/hour |
| Pneumatic | 145 psi ±10%, ≥17.7 SCFM |
| Throughput capacity | 948 lbs/hour |
Dimensions
| Overall dimensions (maximum) | ||
|---|---|---|
| Length | 29 ft 5 in | |
| Width | 8 ft 10 in | |
| Height | 7 ft 10 in |
| Layout | 49 ft 3 in × 26 ft 3 in |
|---|
| Weight (maximum) | 5,512 lbs |
|---|
Purity
| Zinc-carbon, alkaline | 99.5 % |
| All groups | >95 % |
Feedbacks and related links about BATTERAY Classic
Customer Reviews & Installation Videos
Today’s battery waste contains over 200 active formats—differing in size, shape, chemistry, and regulatory classification. Many fall under hazardous waste due to cadmium, lead, or lithium content, making accurate sorting a safety-critical step in recycling.
Traditional sorting systems rely on optical recognition and manual inspection. But in real-world conditions, labels are often missing, degraded, or misleading—leading to misclassification, compliance failures, and contamination of recovery streams.
BATTERAY ZETA takes a fundamentally different approach. Using low-dose X-ray imaging and proprietary machine learning, it classifies each battery by internal structure and material density. This ensures accurate, automated separation—even for damaged, unmarked, or hybrid batteries—and enables the high purity and compliance demanded by modern recycling.
Developed by LINEV Systems, this patented technology replaces guesswork with precision, empowering facilities to meet industrial throughput targets while preparing for evolving regulations and complex chemistries.
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