ActiveFEED Retrofit Electronic Waste

How the optimized material feed with ActiveFEED measurably improves sensor sorting in electronics waste recycling

At its Regensdorf facility, our client, Immark AG, uses the SPALECK ActiveFEED feed hopper to optimize material feed into the sensor sorting system. The goal of the retrofit project was to upgrade the existing system so that different material streams could be processed very reliably and, for the first time, at a defined throughput.

The focus is on the offline sorting of electronic waste—which involves a wide variety of materials and ever-changing requirements for sorting technology.

Leading e-waste recycler in Switzerland
ActiveFEED optimizes material feeding for sensor sorting
Fully automatic, trouble-free material feeding enables highly cost-effective use of the sorting technology
The ActiveFEED retrofit completely resolves previous handling challenges

Optimized Utilization of Sorting Equipment

Highly precise dosing

Optimized Handling

Fully automatic for each material

Pure flexibility

Recipes for Every Type of Material

PROJECT PROFILE

Sensor Sorting in Electronics Waste Recycling

One of the most modern recycling facilities for electronic waste and WEEE in Europe—designed for highly automated operation with high throughput and maximum material recovery.

Customer

Immark AG, Switzerland

Application

Offline Sorting of Electronic Waste

Materials

Non-ferrous metal blends, cables, printed circuit boards, VA blends

Process

Sensor sorting with a downstream sorting booth

Project Type

Retrofit of an Existing Material Feeder

SPALECK SOLUTIONS

IN ACTION

Immark uses these SPALECK machines

Material Feed

ActiveFEED feed hopper

ActiveFEED allows you to optimize the material feed to sorting machines with the push of a button.

Screening machines

Classification of Electronic Waste

In its first project, Immark modernized its e-waste processing facilities at its Regensdorf site. You can find information about the project here:

THE INITIAL SITUATION

Different materials, varying throughput requirements

In its offline sorting process, Immark processes a wide variety of material streams—from cables to mixed non-ferrous metal fractions.

These materials place different demands on the feeding system:

widely varying material properties
Different required throughput rates depending on the material
Uneven material distribution before the sorting process
Blockages in certain material flows
The existing feed system was operating at its limit and became a bottleneck in the process.

Project Goal

Controlled Material Feed for Varying Sorting Requirements

The goal of the project was to design the material feed system so that it could be flexibly adapted to different materials and process requirements.

The focus was on:

The Spaleck Solution

ActiveFEED as a controllable interface to sorting technology

With the retrofit of the SPALECK ActiveFEED, the existing feed system was replaced with a system that actively controls the material flow.

The material feed is no longer controlled manually, but rather based on predefined parameters and recipes. Depending on the material, the optimal amount for sorting is fed into the system.

Automatic adjustment of the task based on the material
even distribution of material across the entire width
Defined feeding of the sensor sorting system
Coordinated transfer to the downstream sorting booth
This ensures that the sorting system receives exactly the amount of material needed for efficient separation.

Customer Benefits

Here's what Immark has to say about the ActiveFEED solution

The ActiveFEED does a very good job with our very different materials.

Our various materials require different throughput rates during sorting. What used to cause problems is now handled very reliably and fully automatically by ActiveFEED. We simply control the materials using recipes, and the downstream sorting equipment is supplied with the set quantity. Furthermore, Blockages or tangles—such as those that occur with cables—no longer occur.

IMPLEMENTATION

Retrofit without altering the existing process logic

The ActiveFEED was integrated into the existing system and replaces the previous feeder.

Today, material feeding is controlled via preset settings. The plant operator selects the appropriate material—ActiveFEED automatically handles the corresponding feeding process.

PROJECT RESULTS

Higher throughput, better sorting quality, and no clogs

The new material feed changes the behavior of the entire sorting line.

Higher throughput due to the elimination of the bottleneck
No more clogs in the feed mechanism
more even distribution of material
Better working conditions for sorting technology
higher sorting quality
This effect is particularly evident with challenging materials such as cable blends: The system can be operated at an adjusted throughput without causing any malfunctions.

COST-EFFECTIVENESS

Getting More Performance from Existing Sorting Technology

In modern recycling, sensor sorting is one of the most expensive components to purchase. It is therefore crucial that these systems operate at optimal capacity during daily operations and that optimal sorting performance is ensured.

Thanks to the controlled material feed:

the sorting system will be fed more evenly
Even the most diverse materials can be processed optimally
the usable throughput increases
the quality of the produced fractions improves
ActiveFEED thus has a direct impact on the performance of the entire line.

TRANSFERABILITY for Your Processing

Relevance for Complex Sorting Processes

The project demonstrates how the material feed affects the performance of sorting systems.

In particular, the solution can be applied to:

Discuss with our experts in screening technology and material feeding

Discuss the next step now

Would you like to learn more about our optimized material feed system for electronics waste recycling? Or do you already have a specific project in mind? Then let’s talk about your materials and your WEEE processing. I’d be happy to show you more references and use cases.

BEST SCREENING. BEST INFEED. FOR THE BEST SORTING QUALITY.

SPALECK Conveyor & Separation Technology in Action

Your contacts for optimal material feeding for electronic waste sorting

We would be happy to advise you in detail on how you can easily optimize your WEEE sorting with the help of ActiveFEED.

Everything You Need to Know

FAQs

Here you’ll find important questions and answers about ActiveFEED, the sorting quality and performance optimizer.

How quickly does the ActiveFEED feed hopper pay for itself?

The ActiveFEED feed hopper pays for itself from day one, as it significantly increases the recovery rate of non-ferrous metals in metal recycling, for example. In many cases, the payback period is less than half a year. We would be happy to advise you personally on this matter. Examples such as STENA Recycling and KMR Recycling show you exactly how this works.

What are the benefits of switching to a SPALECK ActiveFEED feed hopper?

Switching to a SPALECK ActiveFEED feed hopper optimizes material feeding in recycling plants. The constant feed actively prevents sorting equipment from being overloaded or underfed. This improves the quality of sorting in the recycling process and, as a result, expands the options for recycling. Many recyclers report that this allows them to take their sorting to the next level. Take STENA Recycling, for example, as shown in this feedback video.

Can I retrofit the ActiveFEED feed hopper into my system?

Yes, you can easily retrofit the SPALECK ActiveFEED feed hopper. Many of our customers are replacing their standard batch sizes and, as a result, achieving significantly better and more profitable sorting results. Check out this feedback from our client STENA to see how easy the replacement process is.

Can I also use ActiveFEED for XRF or XRT sorting technology?

Yes, the ActiveFEED is ideal as a feeding system for X-ray sorting technology, such as XRF or XRT sorting. In XRF and XRT sorting machines, it enables fully automatic, continuous material feeding. This allows recycling companies to use ActiveFEED to automatically feed their sorting machines with the optimal amount of material for each specific sorting machine and type of recyclable material. This increases both sorting efficiency and volume. In addition, sorting quality can be significantly improved through optimal feeding. See also the case study by STENA Recycling and the recycling expert Skrotfrag.

What sizes is the ActiveFEED infeed unit available in?

The ActiveFEED infeed unit is available in sizes ranging from 2 to 50 m³. We would be happy to advise you on the optimal size for your recycling application.