DESC:FIELD OF THE INVENTION
The present invention relates generally to sorting, segregation, and upcycling from a mixture of plastic waste. More particularly, it pertains to a system and method using advanced sorting mechanisms, Artificial Intelligence (AI), and automation to sort materials from a mixture and produce high-quality recycled polyolefin resins with a distinct process flow.
BACKGROUND OF THE INVENTION
The invention is situated against the backdrop of the complex and critical challenges associated with segregating a mixed stream of post-consumer plastic waste which is available around us and poses significant environmental and operational challenges. Such waste often comprises multiple categories of materials mixing polymers/colors/grade/ food and non-food grade/MFIs of plastic along with inert impurities like dust/metal/moisture/cloth/glass/stone etc. and is difficult to reuse. Manual Segregation and sorting methods are labor-intensive, costly, non-viable, and unsuitable for scalable operations while existing automated solutions often lack efficiency and accuracy.
EP Patent literature holding the Patent No. EP1023945A1 titled "Method and device for sorting a waste mixture" describes mentions of sorting a waste mixture. The waste objects receiving the conveyor surface of the conveyor belt have different mesh sizes across their length to remove different types of impurities. A self-design Nonferrous Separator is installed. The feed can have various categories of material. The module helps in sorting out these categories. The setup is made of sieves, air sorters, and conveyors not specific to eject or reject conveyors. The extrusion process is explained in general. Flake sorting is not mentioned directly. Segregate different types of plastics based on polymer types/color/different grades automatically but artificial intelligence is not explained.

The Patent literature holding the Application No. IN201921012002A with the title "A Method of Separation of Articles" mentions about mentions about separation of articles but is not limited to plastic waste. Material is fed through by conveyor belt. The separation of categories is interpreted as the separation of articles based on grade.
The Patent Application No. BG337816U with title "System for separating, extruding and drying heterogeneous polymer flake" mentions about processing of mixed waste plastic. The feed can have various categories of material. The module helps in sorting out these categories.
The Patent literature bearing Application No. ES03746760T titled "Separation of Plastics with Multiple Stages" mentions the separation of plastics in multiple stages using supplying in conveyor mixture of plastics. The separating device by one of several means including size classification and magnetic exposure if the medium contains a ferromagnetic additive. A three-lane vibrating feeder. The separation, which is based on the entrainment of materials in an ascending air stream. Classifying mixtures with an air sorter, sifting it or treating it on oscillating tables. The invention is performed in specific focus to quality but does not explain quality checks after the sorting process. The dust generated during this grinding process is collected.
Hence, existing systems have limited capabilities in handling complex streams of mixed plastic waste, particularly when multiple categories must be identified and separated efficiently. Many available solutions fail to incorporate AI techniques for high-precision sorting and cannot handle continuous, scalable operations. Furthermore, downstream processes such as grinding, washing, and extrusion to produce food-grade or non-food-grade resins are often inadequate in terms of quality and scalability.
Therefore, it is highly required to solve the complex and critical challenges associated with sorting mixed material and having a stream of post-consumer plastic waste available around us, to ensure continuous and efficient recycling operations.
OBJECTS OF THE INVENTION
The primary object of the present invention is to provide an automated system and method for sorting, segregating, and upcycling mixed plastic waste.
The object of the invention is to achieve cost-effective and scalable segregation using sensors, air sorters, and eject sorters, controlled by microprocessors, to automate the identification, sorting, and segregation of materials in a mixed waste stream.
The object of the invention is to facilitate the separation of recyclable materials into specific categories, supporting subsequent processes like grinding, washing, and extrusion to produce high-quality, reusable materials such as recycled polyolefin resins.
The invention addresses the growing need for automated, accurate, and scalable waste management solutions while contributing to the circular economy by enabling the recovery and upcycling of mixed waste materials.
SUMMARY OF INVENTION:
The present disclosure is directed towards a system for sorting materials from a mixture using sensors to identify material types or physical parameters or both, and generates a sensed data related to identification of mixture. Air sorters, eject sorters, and microprocessors are configured to processes the sensed data generate control signals for air sorters, which push identified materials towards eject sorters. Each eject sorter directs the sorted materials into specific bins. Further, a loop conveyor facilitates iterative sorting by returning unsorted materials to the top of the first conveyor for further processing.

According to one of the embodiment, the system enhances sorting by incorporating the ability to measure the quantity of each material in the mixture. The microprocessor processes this information, enabling precise configuration of air sorters based on both material type and quantity, ensuring that the most significant material categories are sorted efficiently.
According to one of the embodiments, the microprocessor sends signals to prioritize the sorting process by configuring air sorters to eject materials in descending order of quantity. This approach minimizes sorting cycles by targeting the most abundant materials first, increasing system efficiency.
According to one of the embodiments, the system uses or integrates vibro separators on the conveyor belt, loop conveyor belt, or both to optimize sensor performance. The vibro separator spreads and decongests the mixture uniformly, ensuring that each material passes the sensors individually without overlap, thereby enhancing detection accuracy and subsequent sorting precision.
According to one of the embodiments, a feeding section is integrated into the system before sorting, for pre-processing the incoming material mixture. This section includes a de-bailing unit to open bales of mixed materials for further processing, a conveyor with metal capturing capabilities to remove metallic impurities, a Tromil section to employ mesh screens of varying sizes to filter out inert impurities (e.g., dust, glass, stones), magnetic plates to extract ferrous materials and non-ferrous separator to remove nonferrous contents and other non-plastic impurities like stones, glass, and wood, leaving a cleaner mixture for sorting.
According to one of the embodiments, after sorting, a grinding and de-dusting subsystem converts segregated materials into regrinds. A specially designed grinder, equipped with specific blade sizes and nets, processes the materials. Dust generated during grinding is collected in a dust collection unit, which can be reused or further processed to minimize waste.
According to one of the embodiments, the system includes a hot washing subsystem for cleaning the regrinds. The hot washing system comprises a sink-float Tank for separating heavier materials (e.g., PVC, PET) from polyolefin, a friction washer and hot wash reactor for washing at high temperatures with caustic chemicals, a cold wash reactor for further cleaning of regrinds, a spin dryer and thermal dryer to remove moisture and prepare the regrinds for further sorting or extrusion, a label removal unit for removing labels from the regrinds and a de-inking unit adapted to remove inks from the regrinds and a metal separator unit for separating any metallic contamination.
According to one of the embodiments, after washing, the system employs a flake sorting subsystem to sort the washed and dried regrinds, the flakes sorting subsystem comprising a polymer sorter to identify and reject odd or unwanted polymers and a color sorter to remove flakes of undesired colors, ensuring a uniform and high-purity output for the extrusion process.
According to one of the embodiment, an extrusion subsystem converts the sorted and cleaned flakes into recycled polyolefin resins. It comprises two extruders-food-grade extruders and non-food-grade extruders equipped with refresher units to remove volatile organic compounds (VOCs) and odors, producing resins suitable for food packaging and deodorizer units for producing odorless, high-quality non-food-grade resins. The system also comprises a blending system to ensure uniformity in the recycled resins and regrinds feed.
The present disclosure is also directed towards a method for sorting materials from a mixture. The method starts by spreading a material mixture uniformly on a first conveyor belt equipped with multiple sensors. These sensors detect physical parameters such as material type, size, or other characteristics of each item in the mixture. The sensor data is processed by a microprocessor, which generates control signals. These signals configure air sorters placed along the conveyor to push identified materials towards specific eject sorters. The eject sorters then direct the materials into respective bins. A loop conveyor at the bottom collects any unsorted materials and recirculates them back to the top of the conveyor for further sorting iterations, ensuring complete segregation.
According to one of the embodiments, the sensors also measure the quantity of each material in the mixture in addition to identifying their physical parameters. The microprocessor processes both the identification and quantity data to generate control signals. These signals enable air sorters to prioritize sorting materials based on their quantity, ensuring that the most abundant materials are efficiently segregated first.
According to one of the embodiments, the method further refines sorting by prioritizing materials in descending order of their quantity. The microprocessor configures air sorters to eject the most prevalent materials first. This minimizes processing time and ensures that dominant materials are quickly and efficiently sorted, making the system more efficient during iterative sorting cycles.
According to one of the embodiments, the method employs a vibro separator mechanism on the conveyor belt. The vibro separator evenly spreads and decongests the mixture on the conveyor. This step ensures that materials do not overlap, allowing the sensors to detect and classify each material individually, thus improving sorting precision.
According to one of the embodiments, before sorting, the material mixture undergoes pre-processing to remove impurities and prepare it for effective segregation. The pre-processing steps include breaking down bales of mixed materials using a de-bailing unit, filtering out dust, stones, and other inert impurities through mesh screens of varying sizes using Tromil Section, extracting ferrous materials such as iron using a magnetic plate and removing glass, stones, and other non-plastic contaminants using a non-ferrous separator. These pre-processing steps result in a cleaner, more manageable mixture for sorting.

According to one of the embodiments, after sorting, the segregated materials are processed into regrinds using a grinder with predefined blade and net sizes. This grinding step prepares the materials for downstream applications such as washing and extrusion. During grinding, dust and fine particles are generated. Further, dust is captured via a dust collection unit, which can be reused or safely disposed of, minimizing material loss and ensuring cleanliness.
According to one of the embodiments, the method further comprises a detailed multi-stage washing process for cleaning the regrinds. The steps comprising washing the regrinds at a predetermined temperature with caustic and other chemicals using a friction washing unit; separating polyvinyl chloride (PVC) or polyethylene terephthalate (PET) from the regrinds using a sink-float tank; washing the regrinds at a predetermined temperature using a hot wash reactor; removing moisture from the regrinds using a spin dryer; removing labels from the regrinds using a label removal unit; and removing inks from the regrinds using a de-inking unit; and a thermal drying unit for minimizing moisture and a metal separator to detect and separate any metallic contamination.
According to one of the embodiments, the method further comprises rejecting any odd polymers from the regrinds using a polymer sorter; and removing unwanted colors from the regrinds using a color sorter.
According to one of the embodiments, the method further comprises producing recycled low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), high-density polyethylene (HDPE), or polypropylene (PP) granules using an extruder; treating the granules to remove volatile organic compounds (VOCs), odor, and other contaminants for producing food-grade quality resins using a refresher unit; and treating the granules to remove VOCs, odor, and other contaminants for producing non-food grade, odor-free quality resins using a deodorizer unit.
To further understand the characteristics and technical contents along with technical advantages and exemplary data of the present disclosure, a description relating thereto will be made with reference to the accompanying drawings. However, the drawings are illustrative only and not used to limit the scope of the present subject matter.
BRIEF DESCRIPTION OF DRAWINGS
It is to be noted, however, that the appended drawings illustrate only typical embodiments of the present subject matter and are therefore not to be considered for limiting its scope, for the invention may admit to other equally effective embodiments. The detailed description is described with reference number to the accompanying figures. The same numbers are used throughout the figures to reference features and components. Some embodiments of system, method, or structure in accordance with embodiments of the present subject matter are now described, by way of example, and with reference to the accompanying figures, in which:
Figure 1 illustrates a system diagram for sorting materials from a mixture, according to an embodiment of the present invention;
Figure 2 illustrates a complete system architecture of Sorting, Segregation & Upcycling of Mixed Plastic Waste, according to an embodiment of the present invention;
The figures depict embodiments of the present subject matter for the purposes of illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the device and process illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION
The best and other modes for carrying out the present invention are presented in terms of the embodiments, herein depicted in the drawings provided. The embodiments are described herein for illustrative purposes and are subject to many variations. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but are intended to cover the application or implementation without departing from the spirit or scope of the present invention. Further, it is to be understood that the phraseology and terminology employed herein are for the purpose of the description and should not be regarded as limiting. Any heading utilized within this description is for convenience only and has no legal or limiting effect.
The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.
The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more sub-systems or elements or structures or components preceded by "comprises... a" does not, without more constraints, preclude the existence of other, sub-systems, elements, structures, components, additional sub-systems, additional elements, additional structures or additional components. Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment.
For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as would normally occur to those skilled in the art are to be construed as being within the scope of the present invention.

It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not intended to be restrictive thereof.
Unless otherwise defined, all technical and scientific terms used herein have the same meanings as commonly understood by those skilled in the art to which this invention belongs. The system, method, and examples provided herein are only illustrative and not intended to be limiting. Embodiments of the present invention will be described below in detail with reference to the accompanying figures.
Figure 1 discloses a system (100) for sorting a mixture. The sorting mechanism is performed by an Artificial Intelligence (AI) based sorting system. The AI-based sorting system (100) is designed to sort polyolefin post consumer article waste items into various categories of material based on physical parameters such as type, size, color, and texture of the objects. First conveyor belt (104), sensors (101a, 101b, 101c), air sorters (102a, 102b, 102c), microprocessors (103a, 103b, 103c), Eject sorters (107a, 107b, 107c), a Loop conveyor belt (105), Bins (108a, 108b, 108c), and a Vibro separator (106).
The First conveyor belt (104) is the primary conveyor that transports the material mixture through the sorting system. It acts as the backbone of the sorting system, enabling materials to pass through each stage. Further, one or more sensors (101a, 101b, 101c) are placed at different stages along the First conveyor belt (104) to detect the physical parameters of the mixture spread over the conveyor belt. Each microprocessor (103a, 103b, 103c) is connected to its respective sensor (101a, 101b, 101c) and air sorter (102a, 102b, 102c), which is connected with the eject sorter (107a, 107b, 107c).
In an embodiment, the sensors (101a, 101b, 101c) detect specific physical attributes and capture detailed data such as size, shape, color, and surface properties etc.

In other embodiment, air sorters (102a, 102b, 102c) work using one or more image sensors which are placed focusing on the First conveyor belt (104) in the air sorting section. The images captured are processed to determine shape, size, color, shining, and various physical parameters of the objects.
In other embodiment, the sensors (101a, 101b, 101c) identify both the type and quantity of each material in the mixture. The sensors (101a, 101b, 101c) measure the volume of materials passing through the system (100) at a given time. This quantitative data, along with material classification data, is sent to the corresponding microprocessors (103a, 103b, 103c) for further processing.
The sorting system divides the conveyor belt (104) into three section each having sensors (101a, 101b, 101c), air sorters (102a, 102b, 102c), and microprocessors (103a, 103b, 103c) to separate out the mixture of different categories. Initially, the mixture is placed on the first conveyor belt (104). The first section comprised a sensor (101a), air sorter (102a), and microprocessor (103a) to identify and separate out a specific category of material and deposit it into the respective bins (108a). Then the extracted mixture moves to another section comprised of the sensor (101b), air sorter (102b), and microprocessor (103b). This group identifies another category of material and deposits it in to their bins (108b). Lastly, the extracted mixture moves to moves to last section which identifies another category of material and deposits it into their respective bins (108c).
The microprocessor (103a, 103b, 103c) working on an AI technique and machine learning model identifies a category of the object that needs to be sorted. The microprocessor (103a, 103b, 103c) processes the sensed data received from the sensors (101a, 101b, 101c) to identify material categories and generates control signals for air sorters (102a, 102b, 102c) based on material characteristics and sorting logic. The microprocessor (103a, 103b, 103c) generates a first control signal to control air sorters (102a, 102b, 102c) which applies selectively a pressurized air onto the identified object to move to an eject sorter (107a, 107b, 107c). The microprocessor (103a, 103b, 103c) generates a second control signal for configuring the eject sorter (107a, 107b, 107c) to push the received material from the air sorter (102a, 102b, 102c) and guide sorted materials to specific modular bins (108a, 108b, 108c).
In an embodiment, each bin (108a, 108b, 108c) corresponds to a specific category. These bins are strategically placed at the output of the eject sorters to collect segregated materials (1….n). The bins (108a, 108b, 108c) (1…n) correspond to different categories of materials, such as specific polymers, sizes, or colors, and allow efficient storage. The modular bins (108a, 108b, 108c) (1…n) ensure easy handling, storage, and transportation of sorted materials to other downstream processes like grinding and washing, etc.
In other embodiment, materials with higher quantities are prioritized for sorting in the initial passes. The AI-based algorithms running on the microprocessors (103a, 103b, 103c) analyse the sensor data and direct air bursts to segregate the most abundant materials into the corresponding eject sorters (107a, 107b, 107c) and then into specific bins (108a, 108b, 108c). This approach optimizes sorting efficiency by reducing the time required for subsequent iterations of sorting less common materials. For example, in the first loop, the system (100) may direct the air sorter (102a) to target a polymer type with the highest quantity, ensuring faster collection in the bin (108a).
In other embodiment, the first control signal generated by the microprocessor (103) is specifically designed to optimize the sorting efficiency by prioritizing the ejection of materials based on their descending order of quantity. This approach ensures that the most abundant material types in the mixture are processed and segregated first, significantly improving throughput and reducing the time required for sorting less prevalent materials. For instance, if the mixture contains 50% HDPE, 30% LDPE, and 20% PP, the system will prioritize ejecting HDPE first. The air sorter will be configured to eject HDPE into its corresponding bin (108a), followed by LDPE (108b) and finally PP (108c). This systematic approach ensures efficient and accurate sorting while reducing operational delays. This embodiment demonstrates the system's ability to leverage advanced AI-based algorithms and sensor data for intelligent sorting, maximizing efficiency and throughput in handling mixed material streams.
As per Figure 1, system (100) incorporates a loop conveyor belt (105) that collects any unsorted or rejected materials from the bottom of the first conveyor belt (104) and recirculates them back to the first conveyor belt (104) from the top side for another sorting cycle. This iterative process ensures that all materials are sorted with high accuracy. Hence, the loop conveyor belt (105) plays a critical role in iterative sorting.
In an embodiment, the vibro separator (106) is positioned at the start of the sorting system to evenly distribute materials on the First conveyor belt (104). It ensures that the materials are spread out evenly, preventing clumping or overlapping across the First conveyor belt (104), which could reduce sensor accuracy. Additionally, the vibro separator (106) can handle new material streams (109), integrating them seamlessly into the sorting system. By spreading the materials uniformly, the vibro separator (106) prevents overlap or clumping, which could hinder the sensors' (101a, 101b, 101c) ability to accurately identify the materials. In addition to this, the vibro separator (106) filters out fine particles and dust from the mixture, ensuring that only sortable materials proceed through the sorting system. This step is critical in enabling the sensors (101a, 101b, 101c) to capture accurate data about each material, allowing the downstream processes controlled by the air sorters (102a, 102b, 102c) and eject sorters (107a, 107b, 107c) to function effectively. The vibro separator (106) also integrates with the new stream input (109) to allow for continuous addition of fresh material streams without disrupting the sorting process.
This intelligent, automated sorting system (100) optimizes material recovery and prepares segregated materials, which are subsequently processed by the grinding and de-dusting section, hot washing section, flake sorting section, and extrusion section, performing grinding, cleaning, polymer sorting, color sorting, and extrusion, ultimately contributing to a sustainable recycling workflow.
Figure 2 illustrates a complete system architecture (200) for the sorting, segregation, and upcycling of mixed plastic waste, starting from pre-processing and integrating multiple subsystems to producing high-quality recycled materials through downstream feeding section (201). The modular architecture of system (200) incorporate AI-based sorting (100), grinding (202), washing (203), flake sorting (204) and extrusion (205), ensures scalability and efficiency in addressing the challenges of waste segregation and upcycling.
The process begins in the Feeding Section (201), where the mixed plastic waste is received and fed through a feeding platform or pre-processed to remove contaminants and prepare it for sorting. This section includes a De-baling unit (201a) to unwrap the mixed plastic waste and spread it for further processing. This unit (210a) ensures that materials are separated and ready for inspection.
A Belt Conveyor System (201b) is a critical component of the feeding section in the overall waste segregation and upcycling system. The conveyor (201b) consists of a durable and abrasion-resistant endless belt made of rubber or synthetic material, reinforced with high-strength fiber to handle heavy mixed plastic loads. The belt (201b) is mounted on a robust steel frame with rollers for smooth and continuous operation. The frame includes adjustable tensioners to maintain belt alignment and prevent slippage. Additionally, the belt width and speed are optimized to accommodate the high throughput of plastic waste.
Further, a high-intensity permanent magnet or electromagnetic coil housed in a protective casing is installed above or within the conveyor belt to remove ferrous materials like nails, wires, and metallic debris. As the waste travels along the conveyor, the magnet/coil generates a magnetic field that attracts ferrous metals from the waste stream. These metallic impurities adhere to the magnet while the rest of the material continues along the conveyor. Once the metallic impurities are captured, they are diverted away from the conveyor and deposited into the collection bin. This magnet/coil removes metallic contaminants before the waste enters more sensitive sorting stages, such as sensor-based or AI-driven systems. It enhances the efficiency and accuracy of downstream processes.
After the removal of metallic impurities, the mixture feeds into Tromil section (201c) mesh screens of varying sizes to remove inert impurities like glass, fine dust, and stones. This section (201c) provides an initial level of cleaning by separating out non-plastic contaminants.
Further, a magnetic plate (201d) is installed to remove metallic contents from the mixture of waste streams. Lastly, a non-ferrous separator (201e) is designed to remove non-ferrous metallic impurities from mixed material streams. These impurities, such as aluminum, brass, copper, and other non-magnetic metals, cannot be removed using traditional magnetic separators and therefore require non-ferrous separators (201e). The Non-Ferrous Separator (201e) operates on the principle of eddy currents, which are induced in conductive (metallic) materials when exposed to a rapidly changing magnetic field. These eddy currents create a secondary magnetic field in the non-ferrous metals, opposing the magnetic force. This causes the non-ferrous metals to be repelled and thrown away from the rest of the waste stream. A self-design Nonferrous Separator (201e) is installed to remove mud/stone/glass/non-plastic objects etc. to ease the automatic sorting operations. Hence, the waste stream entering downstream processes is free of ferrous, non-ferrous metallic contaminants and inert impurities.
Now the cleaned plastic waste enters the Sorting System (100), which is an AI-based automated mechanism for segregating materials. This subsystem identifies materials using sensors (101a, 101b, 101c) and separates them based on physical parameters like size, shape, color, and polymer type. The detailed working of this system has already been described (refer to the explanation of Figure 1). The output is a categorized waste stream ready for downstream processing.

In an embodiment, the material stream is spread using a vibro separator, which prevents overlapping and filters out fine dust particles.
In an embodiment, the first control signal is generated for configuring air sorters for ejecting out materials by descending order of quantity of each of the identified material.
Furthermore, a wet grinding and de-dusting subsystem (202) is adapted after sorting, to convert the sorted materials into regrinds which leads to size reduction and cleaning. The wet grinding and de-dusting subsystem (202) includes a grinder (202a) with water circulation and a dust collection unit (202b). The grinder (202a) feature with blades and nets with predefined sizes to achieve uniform granulation. Continuous water circulation in grinder (202a) support frictional wash of regrinds. The grinder (202a) reduce the size of segregated materials into regrinds suitable for washing and further processing. The dust collection unit (202b) captures fine dust particles generated during the grinding process and ensures a cleaner output and minimizes material loss. Also, the dust generated during this grinding process is collected back and used. This subsystem (202) outputs finely ground, dust-free plastic regrinds suitable for better washing exposure.
The regrinds are cleaned in a Hot Washing Subsystem (203), which removes contaminants like labels, adhesives, and inks. A specially designed washing section is set up to clean the post-consumer regrinds to produce clean and clear regrinds for further flakes level sorting. The Hot Washing Subsystem (203) comprises one or more stages such as a sink-float tank (203b) for separating heavier contaminants like polyvinyl chloride (PVC) or polyethylene terephthalate (PET) from the regrinds and other heavy non-polyolefin from lighter polyolefin using density-based separation. A friction washing unit (203a) for washing the regrinds at a predetermined temperature with caustic and other chemicals. The grinds are subject to friction washing at 85°C under caustic and other chemicals for 15 minutes followed by a sink floating tank (203b) to separate out PVC or PET etc. This unit uses mechanical friction and water to scrub surface impurities from the regrinds. A hot wash reactor (203c) for washing the regrinds impurities at a predetermined temperatures. A de-inking unit (203d) eliminates remaining printing inks or dyes from the plastic, ensuring clean regrinds. A cold wash reactor (203e) for further cleaning of regrinds to remove impurities. A spin dryer (203f) for cleaning and removing residual moisture from the washed regrinds. A label removal unit (203g) specifically designed to detach and remove labels from the plastic regrinds. A thermal Dryer unit (203h) to further reduce the moisture of regrinds. Lastly, a metal separator unit (203i) to remove any metallic contents from regrinds.
The washed materials proceed to the flake sorting subsystem (204).
In the Flake Sorting Subsystem (204), the washed and dried regrinds are further refined and sorted. The Flake Sorting Subsystem (204) comprises a polymer sorter (204a) rejects odd or unwanted polymers. In other words, the polymer sorter (204a) separates flakes based on polymer type. The Flake Sorting Subsystem (204) further comprises a color sorter (204b) for removing unwanted colors from the regrinds to produce uniform and consistent output. The flake sorting subsystem (204) provides a clear or hot washed or dried polymer regrinds of desired polymer and colour and ensures the highest level of purity for the materials, making them ready for extrusion (205).
The clean, sorted flakes are processed in the Extrusion Subsystem (205) to produce recycled polyolefin resins. The extrusion subsystem comprises a Food Grade extruder (205b) and Non-Food Grade Extruder (205e) producing flakes into granules such as recycled low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), high-density polyethylene (HDPE) or polypropylene (PP) granules of injection moulding, blow moulding, pipe grade, thermoforming, film grade etc. A blending system (205a) is used at the start of extrusion system (205) to make a uniform blend of regrind to ensure uniform quality feed to extruders. For food grade segment a refresher unit (205c) is connected after the extruder (205b) which treat the granules at defined temperature and under special conditions for certain time period to remove volatile organic compounds (VOCs), odors and other contaminants for producing food-grade quality resins, ensuring compliance with food-grade standards. For Non-Food Grade segment a deodorizer unit (205f) is connected after the extruder (205e) which treat the granules at defined temperature and under special conditions for certain time period to eliminate VOCs, odor, and other contaminants for producing non-food grade, odor-free quality resins, and enhancing quality for industrial applications. Lastly, a blending system (205d, g) for blending of granules at outlet of extruders to ensure uniform mixing of granules for food grade and Non-food grade.
Hence, Figure 2 represents a complete system architecture (200), integrating multiple interconnected subsystems (201-205) to achieve the efficient sorting, segregation, and upcycling of mixed plastic waste. The system is designed to handle complex material streams by employing specialized components and sequential processes to ensure high-quality outputs, such as recycled polyolefin resins. Each subsystem is designed to address specific challenges in waste processing, ensuring scalability, efficiency, and environmental sustainability.
Hence, the architecture (200) ensures scalability, automation, and high-quality outputs, making it a key innovation in waste management and upcycling processes.
The instant solution also provides a system and method for sorting materials from a mixture. The process starts with a feeding section for pre-processing and ensures that the mixed plastic waste stream is cleaned and prepared for sorting. In sorting, the material stream is evenly spread across the first conveyor belt having sensors for detecting the physical attributes of each item in the waste stream. Once materials are sorted, they are size-reduced into flakes in the Grinding and De-Dusting Subsystem. Sorted materials are fed into a grinder equipped with blades and nets of predefined sizes to produce uniform regrinds. Further, the cleaning steps includes Hot Washing Subsystem to remove impurities from the granules or flakes, ensuring high purity. Furthermore, refining of material ensures the purified material meets the required specifications for polymer type and color using the flake sorting subsystem. Hence, the output is a homogenous stream of flakes with consistent color and polymer composition. The final step involves converting the refined flakes into recycled resins through extrusion. Hence, the resulting granules or resins are high-quality, ready for reuse in manufacturing applications, including packaging, films, and industrial products. ,CLAIMS:We Claim:
1. A system (100) for sorting materials from a mixture comprising:
- a plurality of sensors (101(a, b, c)) placed on a first conveyor belt (104) wherein the mixture is spread uniformly, the sensors (101) are adapted to sense physical parameter, type of material, or combination thereof of each of the materials in the mixture and to generate a sensed data related to identification of each of the mixture;
- one or more air sorters (102(a, b, c)) placed along the first conveyor belt (104);
- one or more eject sorters (107(a, b, c)), wherein each of the eject sorters (107) is coupled to each of the air sorters (102) and to a plurality of bins (108 (a, b, c)(a----n));
- one or more microprocessors (103 (a, b, c)) coupled to one or more air sorters (102 (a, b, c)), and adapted to receive the sensed data from the sensors (101(a, b, c)) and to process the sensed data to generate a first control signal for configuring each of the air sorters (102(a, b, c)) based on the identification of the materials for transferring one of the identified material is pushed towards a specific eject sorter (107) , and to generate a second control signal for configuring the eject sorter (107) to push the received material from the air sorter (102) towards one of the plurality of bin (108 (a, b, c)(a----n)); and
- a loop conveyor belt (105) coupled to a bottom end of the first conveyor belt (104) downwards of the placement of the air sorters (102) and to a top end of the first conveyor belt (104) and adapted to receive the mixture remaining after an iteration of sorting of the material from the bottom end of the first conveyor (104) and to transfer it to the top end of the first conveyor (104) for a next iteration of sorting of the mixture.

2. The system (100) as claimed in claim 1, wherein the physical parameter includes a quantity of each of the material in the mixture, and the microprocessor (103) is adapted to receive and process of quantities of each of the material in mixture along with the identification of each of the material, and is adapted to generate the first control signal for configuring air sorters (102) based on the identification of the materials and quantity of the materials.

3. The system (100) as claimed in claim 2, wherein the first control signal is generated for configuring air sorters (102) for ejecting out materials by descending order of quantity of each of the identified material.

4. The system (100) as claimed in claim 1, wherein one or both of the conveyor belts (104) functionally coupled to a vibro separator (106) for spreading and decongesting the mixture uniformly for sensors (101) to work upon them.

5. The system (100) as claimed in claim 1, further comprising a feeding section (201) adapted to receive the mixture before sorting, the feeding section (201) comprising:
- a de-bailing unit (201a) for opening of bails of mix materials;
- a Belt Conveyor system (201b) with Metal Capturing capabilities;
- a Tromil section (201c) having different mesh sizes for removing different types of inert impurities from the mixture;
- a magnetic plate (201d) for removing metallic contents from the mixture; and
- a non-ferrous separator (201e) for removing Nonferrous contents and other non-plastic objects from the mixture.

6. The system (100) as claimed in claim 1, further comprising a grinding and de-dusting subsystem (202) adapted to convert the sorted materials into regrinds suitable for washing, the grinding and de-dusting system (202) comprising:
- a grinder (202a) with water circulation having a predefined size of net and blades for converting the sorted materials into regrinds; and
- a dust collection unit (202b) for collecting and reusing dust generated during the grinding process.

7. The system (100) as claimed in claim 6, further comprising a hot washing subsystem (203) adapted to clean the regrinds, the hot washing subsystem (203) comprising:
- a friction washing unit (203a) for washing the regrinds at a predetermined temperature with caustic and other chemicals;
- a sink-float tank (203b) for separating polyvinyl chloride (PVC) or polyethylene terephthalate (PET) from the regrinds and other heavy non polyolefin;
- a hot wash reactor (203c) for washing the regrinds at a predetermined temperature;
- a de-inking unit (203d) adapted to remove inks from the regrinds;
- a cold wash reactor (203e) for further cleaning of regrinds;
- a spin dryer (203f) for cleaning and removing moisture from the regrinds;
- a label removal unit (203g) for removing labels from the regrinds;
- a Thermal Dryer unit (203h) to further reducing the moisture of regrinds; and
- a metal separator unit (203i) for removing any kind of metals.

8. The system (100) as claimed in claim 7, further comprising a flakes sorting subsystem (204) adapted to sort the washed and dried regrinds, the flakes sorting subsystem (204) comprising:
- a polymer sorter (204a) for rejecting any odd polymers from the regrinds; and
- a color sorter (204b) for removing unwanted colors from the regrinds.

9. The system (100) as claimed in claim 8, further comprising an extrusion subsystem (205) adapted to produce recycled polyolefin resins, the extrusion subsystem (205) comprising a first blending system (205a) for blending of regrinds before a food-grade extruder subsystem (206a) and non-food-grade extruder subsystem (206b),

wherein the food grade extrusion subsystem (206a) comprising:
- a food grade extruder (205b) producing recycled low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), high-density polyethylene (HDPE), or polypropylene (PP) granules;
- a refresher unit (205c) for treating the granules to remove volatile organic compounds (VOCs), odor, and other contaminants for producing food-grade quality resins; and
- a second blending system (205d) for blending of food grade resins at outlet of food grade extruder;

wherein the non-food grade extrusion subsystem (206b) comprising:
- a non-food-grade extruder (205e) producing recycled low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), high-density polyethylene (HDPE), or polypropylene (PP) granules;
- a deodorizer unit (205f) for treating the granules to remove VOCs, odor, and other contaminants, producing non-food-grade, odor-free resins; and
- a third blending system (205g) for blending of non-food grade resins at the outlet of the non-food-grade extruder.

10. A method for sorting materials from a mixture, comprising:
- spreading the mixture uniformly on a first conveyor belt having a plurality of sensors;
- sensing physical parameters, types of materials, or a combination thereof of each material in the mixture using the sensors and generating sensed data related to identification of each material;
- receiving the sensed data by a microprocessor and processing the sensed data to generate a first control signal;
- configuring air sorters, placed along the first conveyor belt, based on the identification of the materials using the control signals from the microprocessor; and
- pushing one or more identified materials towards a specific eject sorter;
- generating a second control signal for configuring the eject sorter to push the received material from the air sorter towards one of the plurality of bin;
- receiving the mixture remaining after an iteration of sorting of the material by a loop conveyor belt from a bottom end of the first conveyor and transferring it to a top end of the first conveyor for a next iteration of sorting of the mixture.

11. The method as claimed in claim 10, wherein the physical parameter includes a quantity of each of the material in the mixture, the method comprising:
- receiving and processing of quantities of each of the material in mixture along with the identification of each of the material by the microprocessor; and
- generating the first control signal for configuring air sorters based on the identification of the materials and quantity of the materials.

12. The method as claimed in claim 11, wherein the first control signal is generated for configuring air sorters for ejecting out materials by descending order of quantity of each of the identified material.

13. The method as claimed in claim 12, further comprising spreading the mixture uniformly on the conveyor belt using a vibro seperating mechanism prior to being acted upon by the sensor.

14. The method as claimed in claim 10, further comprising:
- Debailing of waste materials from the mixture using a de-bailing unit;
- removing different types of impurities from the mixture using a Tromil section having different mesh sizes;
- removing metallic contents from the mixture using set of magnetic plates; and
- removing non-plastic/nonferrous objects from the mixture using a non-ferrous separator.

15. The method as claimed in claim 10, further comprising:
- converting the sorted materials into regrinds suitable for washing using a grinder having a particular size of net and blades; and
- collecting and reusing dust generated during the grinding process using a dust collection unit.

16. The method as claimed in claim 15, further comprising:
- washing the regrinds at a predetermined temperature with caustic and other chemicals using a friction washing unit;
- separating polyvinyl chloride (PVC) or polyethylene terephthalate (PET) from the regrinds using a sink-float tank;
- washing the regrinds at a predetermined temperature using a hot wash reactor;
- removing inks from the regrinds using a de-inking unit
- removing moisture from the regrinds using a spin dryer;
- removing labels from the regrinds using a label removal unit; and
- removing metallic particles from the regrinds using a metal separator unit.

17. The method as claimed in claim 16, further comprising:
- rejecting any odd polymers from the regrinds using a polymer sorter; and
- removing unwanted colors from the regrinds using a color sorter.

18. The method as claimed in claim 17, further comprising a food-grade extrusion method flow sequence and a non food-grade extrusion method flow sequence operating simultaneously after blending to optimize the production of food-grade and non food-grade recycled polyolefin resins,
wherein the food-grade extrusion method flow sequence comprising :
-extruding the blended reprints through a food-grade extruder, to produce recycled low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), high-density polyethylene (HDPE), or polypropylene (PP) granules;
- treating the granules a refresher unit, to remove volatile organic compounds (VOCs), odor, and other contaminants for producing food-grade quality resins; and
- blending of food grade resins through a second blending system, at the outlet of the food-grade extruder;

wherein the non food-grade extrusion method flow sequence comprising:
- extruding the blended reprints through a non food-grade extruder, to produce recycled low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), high-density polyethylene (HDPE), or polypropylene (PP) granules;
- treating the granules in a deodorizer unit, to remove VOCs, odor, and other contaminants for producing non-food grade, odor-free quality resins; and
-blending of non-food grade resins through a third blending system, at the outlet of the non food-grade extruder.