Innovation in Action: Recycleye Smart Sorting Arm Debuts at Recorra MRF

The future of sorting is finally here! Our state-of-the-art, AI-powered robotic sorting arm, developed by Recycleye, is fully operational and was installed on the 17th of July at our Materials Recovery Facility (MRF)! This makes Recorra the first commercial-only MRF in the UK to implement this cutting-edge technology, marking a major milestone in our £1 million MRF investment.

Our team worked closely with Recycleye to install, test, and fine-tune the robotic arm over the last six months, ensuring seamless integration into our sorting process. Now, the system is ready to deliver enhanced efficiency, accuracy, and safety, transforming how we process recyclables. 

How we got here

Stage 1: December 2024 – February 2025

Vision System Installation and AI Learning   

The vision system was installed at our MRF in January 2025 to learn how to analyse material composition and target item distribution by monitoring materials on our conveyor belt.

Stage 2: February – May 2025

Fabrication and Preparation   

The AI sorting robot and permanent vision system were constructed while modifications were made to our MRF to accommodate the new technology.  

Stage 3: June – August 2025

Fabrication and Optimisation  

After comprehensive testing, the sorting robot was installed at our Purfleet MRF. It will continue to undergo analysis for further optimisation.  

How the AI-Powered Sorting Arm Works

The robotic system combines AI vision, machine learning, and precision robotics to identify and sort materials at remarkable speeds. Here’s how it operates: 

• AI Vision Unit: A high-resolution camera and AI processor scan the sorting belt in real time, instantly recognising our target materials: cardboard, plastics, and coffee cups. 

• Robotic Arm: Guided by AI, the arm extends across the belt, swiftly picking and placing materials into dedicated bins. 

• Vacuum Extractor Unit: A suctioned gripper gently lifts and deposits items, ensuring minimal damage and maximum efficiency. 

• Sorting Speed: Capable of processing 35 to 60 items per minute, the arm works tirelessly. 

• Data Analytics: An integrated dashboard provides real-time waste composition insights, helping us optimise operations further. 

Key Benefits of Our AI-Powered Sorting Arm

Improved Safety

The waste industry is one of the most hazardous due to heavy machinery and repetitive tasks. By automating part of the sorting process, we reduce manual labour in high-risk areas, allowing staff to transition into safer roles.

Increased Efficiency & Throughput

Unlike human sorters, the robotic arm operates continuously, maintaining consistent speed and accuracy. This boosts our MRF’s overall capacity, allowing us to process recyclables more efficiently.

Enhanced Sorting Accuracy

The AI’s machine-learning algorithms identify materials with near-perfect precision, drastically reducing contamination and improving the quality of our recyclable output. This ensures more materials are correctly recovered and repurposed.

Future Adaptability

While currently trained to sort cardboard, plastics, and coffee cups, the system can be re-trained to handle new materials as legislation and waste streams evolve. This future-proofs our MRF against changing industry demands. 

What’s Next?

At Recorra, innovation drives everything we do. From smart collection methods to circular recycling solutions, we’re committed to sustainability, efficiency, and workplace safety.  

We will continue working with Recycleye to fine-tune the sorting arm’s pick rate and target item recovery, analysing data in real time to optimise this new tool as much as possible.  

This installation is just the first phase of our £1 million MRF upgrade. If the robotic arm proves as successful as expected, we may expand automation further, increasing our facility’s capacity and operational hours. 

Stay tuned for updates on our AI sorting arm’s performance by following us on social media and checking back here in the coming months.