Plastic Film Sorting | AISORT
Application Overview — Plastic Recycling
Plastic Film Sorting in Modern Recycling Facilities
Plastic film and flexible packaging represent roughly 40% of plastic packaging by weight but less than 10% of plastic recycling. Closing this gap requires specialized sorting systems that handle the unique behavior of film materials: low weight, high surface area, tendency to wrap, fold, and bridge. Film sorting lines separate LDPE/LLDPE film (the most recyclable film type) from PP film, multi-layer laminates, and non-plastic contaminants.
Material Characteristics and Sorting Challenges
Film sorting challenges: films are lightweight and aerodynamic — they behave unpredictably on conventional chutes and belts; multi-layer films (e.g., PET/PE/AL laminates for food packaging) cannot be mechanically recycled and must be identified and separated; printed films have a different NIR signature from unprinted films of the same polymer; and film is often the most contaminated fraction in the recycling stream (food residues, paper labels, mixed materials).
Recommended Sorting Technology Stack
NIR (polymer identification of film type — LDPE vs PP vs PET vs multi-layer) + 3D laser (film thickness measurement for multi-layer detection) + RGB (color and print detection). Specialized handling: anti-static systems to prevent film clinging; air-knife separation for lightweight material; high-friction belts to prevent film sliding. Pre-washing strongly recommended.
Performance Benchmarks
| Metric | Target |
|---|---|
| Film Type Accuracy | >95% |
| Multi-Layer Detection | >90% |
| Throughput | 1-4 t/h (film) |
| Film Size | A4+ sheet size |
These benchmarks represent achievable performance with modern sensor-based sorting equipment, assuming properly sized, well-maintained equipment operating on representative feedstock. Actual results depend on specific material composition, throughput, and operating conditions.