AI solution upgrades wrought aluminum scrap

TOMRA Recycling has expanded its portfolio to incorporate a new AI-based solution that upgrades wrought aluminum scrap recycling. The development is the first application of GAINnext — TOMRA's deep learning-based sorting technology — in the metals industry.

The AI innovation enables aluminum scrap processors and recyclers to upgrade their wrought aluminum scrap and produce high-purity fractions by quickly recovering low-alloy cast from the wrought fraction and reducing alloy elements like silicon. GAINnext complements TOMRA's X-TRACT system, which separates metals based on atomic density. 

Achieving a high-quality fraction

TOMRA's X-TRACT, featuring X-ray Transmission technology, sorts aluminum from heavy metals based on atomic density. X-TRACT initially sorts shredded mixed non-ferrous metals (Zorba) to produce high-purity aluminum scrap (Twitch), then removes high-alloy aluminum cast and high-density wrought aluminum to further refine the Twitch. This process yields a high-quality fraction, containing both wrought aluminum and minor amounts of low-alloy cast. 

A pure wrought fraction can be achieved by integrating the GAINnext into the sorting process after X-TRACT. GAINnext uses deep learning and artificial neural networks. Using RGB cameras, it rapidly processes tens to hundreds of thousands of images per millisecond, classifying materials by shape, size, and dimension with accuracy.

The system mimics human vision but with better speed, facilitating high throughput sorting of up to 2,000 ejections per minute. In its first metals industry application, by detecting and removing low-alloy cast from the wrought fraction that TOMRA's X-TRACT produces, GAINnext delivers a high-purity wrought product that allows for premium market prices.

TOMRA continues to build on its AI strategy

Recyclers and metal processors looking to achieve even higher granularity levels in aluminum sorting, the wrought fraction recovered by GAINnext can be refined even more using TOMRA's AUTOSORT PULSE system that employs dynamic laser-induced plasma spectroscopy (dynamic LIBS) for precise identification and sorting of different alloy types.

Launched in 2023, AUTOSORT PULSE leverages precise elemental composition analysis and advanced dynamic laser detection to accurately distinguish between different alloy types, e.g. 5xxx and 6xxx aluminum. 

Tom Jansen, head of sales for the metals segment at TOMRA Recycling, comments: "We are excited to launch this new deep learning-based application to upgrade wrought aluminum. Deep learning is a powerful addition to our traditional sensor-based technology, and expanding our GAINnext ecosystem aligns with our broader AI strategy. Building on our proven success and the significant results our customers have achieved with GAINnext in the waste segment, we are confident in delivering similar value to our metals customers."

"Our latest innovative solution optimizes dry mechanical sorting of mixed metals," adds Giuseppe Petro Granara, segment manager of metals for the Americas at TOMRA Recycling. "Along with complementing other technologies within the TOMRA portfolio, GAINnext provides a highly efficient, cost-effective alternative that minimizes manual labour and maximizes throughput. Its low cost per ton makes it an attractive option for recyclers aiming to consistently produce smelter-ready, high-purity aluminum. Beyond metal recycling, the technology's adaptability opens opportunities for use in other industries requiring manual sorting."