Before any machine existed, quality was always checked by a human. Imagine a scene from one hundred, two hundred, or even thousands of years ago: a farmer or a worker sitting at a table, running grain through their hands, picking out with their eyes what should be discarded: a stone, a damaged kernel, a remnant of husk. It was monotonous, eye straining, and incredibly time consuming work, but for centuries, it was the only available method for ensuring quality.

Manual selection had one fundamental weakness: it depended on human perception, and perception is fickle. Fatigue, poor lighting, and the monotony of repetitive movements all impacted effectiveness. Despite this, this method lasted longer than any other and still functions today in many parts of the world where the scale of production does not justify the investment in automation.

The First Mechanical Attempts: The Power of Physics to the Rescue

The Industrial Revolution brought the first attempts at mechanizing selection: sieves, shakers, and gravity separators that utilized differences in weight, density, and size. This was a huge leap forward in terms of efficiency, but it was still very limited. These machines could distinguish big from small or heavy from light, but they had no concept of color, surface defects, or internal damage. Furthermore, a human was still needed as the final line of quality control.

1947 – The Birth of Optical Sorting

The breakthrough came in the mid-20th century when engineers began experimenting with photocells – simple sensors that reacted to light. The first devices of this type, used mainly in the food industry (e.g., for sorting beans or peas), worked on a very basic principle: they detected the difference in hue between a “good” product and a darker contaminant, after which a stream of air removed the unwanted element from the line.

This was the moment when, for the first time, a machine began to “look” at the product, rather than just reacting to its mass or size. Photocells were primitive compared to today’s systems. They recognized mainly black and white contrast or simple shade differences, but conceptually, they opened the door to everything that followed.

The Era of Cameras and Digital Image Processing

The 1980s and 90s were a time when the development of electronics and computer science enabled the use of real cameras in sorting processes. Instead of a single photocell reacting to one parameter, machines began to “see” the entire image of the product – its color, contour, and surface texture. Computers, though still computationally limited by today’s standards, were already able to analyze images in real-time and make decisions dozens of times per second.

It was at this stage that optical sorting began to resemble the technology we know today: line scan cameras, lighting with specific characteristics, and pneumatic nozzles removing contaminants with incredible precision. The food industry, fruit and vegetable processing, and the recycling industry all began to discover that a machine could perform the work of many pairs of human eyes simultaneously, without losing concentration after an eight hour shift.

Seeing Beyond the Human Eye

The next step was to go beyond what a human sees. The introduction of cameras working in Near Infrared (NIR), as well as multispectral and hyperspectral technology, allowed machines to detect differences invisible to the human eye, such as internal product damage, early stages of mold, or differences in chemical composition and moisture. The sorter was no longer just a “better eye,” but an analytical tool that provided information previously unattainable in any other way.

This was the moment when optical sorting stopped competing with humans on the same terms and began offering a completely new level of control. Unattainable before, regardless of an employee’s experience or attention.

Artificial Intelligence and Machine Learning

The latest, ongoing revolution is the entry of machine learning algorithms. Earlier systems operated on rigidly programmed rules: “if the pixel is darker than value X, reject the object.” Today’s systems, based on neural networks, “learn” from thousands of examples, recognizing patterns too complex to describe with a simple rule.

As a result, a machine can, for example, learn to distinguish a natural, acceptable discoloration from a defect that requires rejection. It is a level of discrimination that previously required an experienced human eye. Moreover, these systems can be trained in real time, adapting to a changing batch of raw material or a new type of contaminant that has never appeared before.

From Sifting Stones to Millisecond Decisions

Looking at this history from a distance, a clear line of development emerges: from physical separation, through simple contrast detection, to intelligent systems that analyze images in a spectrum inaccessible to the human eye and make decisions at a speed impossible for a human to achieve. Each stage of this evolution answered the same question the farmer sifting grain through their hands asked: how to separate the valuable from that which should not move forward. The fundamental difference is that machines can do it faster, more precisely, and without fatigue.

What began as a simple necessity is now one of the most advanced fields of industrial automation, combining optics, electronics, and artificial intelligence into one smoothly operating process.

Modern Technologies Serving Optical Sorting

What started as a simple optical electrostatic setup has evolved over the decades into increasingly advanced systems:

• Color cameras and line-scan cameras replaced simple sensors, enabling the detection of much subtler color and texture differences.
• Near Infrared (NIR) technology allowed machines to “look” under the surface of the product to detect moisture, chemical composition, or damage invisible to the naked eye.
• Hyperspectral cameras expanded the detection range to dozens or even hundreds of light bands simultaneously.
• Maglev ejectors – beyond cameras, the ejection itself matters. Modern air systems precisely remove defective particles from the stream without wasting good material.
• Artificial Intelligence and Deep Learning technology, present in the latest generations of sorters, allow the machine to independently “learn” to recognize new types of defects based on thousands of analyzed images, without the need for manual programming of every parameter.

Summary

The history of sorting is, in essence, the history of gradually transferring one human skill to machines: first strength and endurance, then sight, and today, the ability to learn and make decisions. From a single worker sifting grain by hand, through mechanical sieves, photocells, and cameras, to systems utilizing artificial intelligence and precision air ejectors. Every stage of this journey answered the same question: how to distinguish good from defective faster, more accurately, and on a larger scale. What began as a purely human task has today become one of the most technologically advanced fields of industrial automation.

The post A Brief History of Sorting: From Manual Selection to Artificial Intelligence appeared first on Meyer Europe.

From 19–22 May, Plastpol 2026 took place in Kielce, once again confirming its position as one of the most important meeting points for professionals from the plastics and recycling industries in Central Europe.

Throughout the exhibition, the MEYER Europe stand welcomed a steady flow of visitors, creating an excellent opportunity to exchange ideas, discuss current market developments and explore the growing role of optical sorting technologies in modern recycling processes.

One of the highlights for our team was the opportunity to host representatives of the Polish Recycling Association. We were delighted to welcome them to our stand and greatly appreciated the opportunity to discuss the future of recycling and the challenges facing the industry today.

What made this year’s event particularly rewarding was the diversity of visitors. We had the pleasure of meeting many new customers who were looking for innovative sorting solutions, while also reconnecting with long-standing partners, industry colleagues and friends from across the recycling sector.

Events such as Plastpol remind us that technology is only part of the story. Progress is built through conversations, shared experiences and strong industry relationships. We would like to thank everyone who visited the MEYER Europe stand and contributed to making this year’s exhibition such a successful and memorable event.

We look forward to continuing the discussions started in Kielce and to seeing many of you again soon.

The post Plastpol 2026 Brought the Industry Together appeared first on Meyer Europe.

On 5-6 May, the MEYER team joined industry professionals from across Europe at PRSE 2026 in RAI Amsterdam, one of the key events dedicated to plastics recycling and circular economy solutions.

This year’s edition stood out for a reason. Throughout the exhibition halls and conference areas, there was a clear sense that the recycling industry is regaining momentum. Visitors arrived with concrete projects, investment plans and a genuine interest in technologies that can help improve material recovery and product quality.

For MEYER, the event proved exceptionally productive. Our team spent two intensive days discussing optical sorting solutions with recyclers, processors and technology partners. The conversations focused on current challenges facing the industry, emerging market opportunities and the growing role of advanced sorting technologies in achieving higher purity levels and more efficient recycling processes.

As our Executive Director, Vincent Kundrat, summarized after the event, the atmosphere at PRS Europe reflected a market that is gradually rebuilding confidence and preparing for the next stage of growth. The quality of discussions and the level of engagement from visitors were particularly encouraging.

We would like to thank everyone who visited the MEYER stand, shared their experiences and explored new possibilities with our team. We appreciate every conversation and look forward to continuing them in the months ahead.

The post MEYER at PRS Europe 2026: The Industry Is Moving Forward Again appeared first on Meyer Europe.

Immediate cost considerations

Traditional manual sorting operations typically require extensive labor forces, with multiple workers stationed along conveyor belts to identify and remove defective or unwanted items. While the upfront costs are minimal, the ongoing expenses are significant:

Traditional sorting annual costs:

• Labor wages and benefits for sorting staff
• Training and supervision expenses
• Quality control oversight
• Workplace injury-related costs
• Production line slowdowns

In contrast, optical sorting systems represent a substantial initial investment, often ranging from € 30,000 to € 400,000 per unit. However, this technology brings immediate reductions in operating costs and staffing requirements.

Efficiency and productivity gains

Optical sorting machines can process even several tons of material per hour, depending on the type of material and its level of contamination, significantly outpacing manual sorting methods. This increased throughput translates to:

• Higher production capacity without additional shifts
• Reduced labor costs per unit processed
• Consistent quality standards across all production hours
• Minimal downtime for breaks or shift changes
• 24/7 operation capability with minimal supervision

Quality Improvements and waste reduction

Modern optical sorters utilize advanced imaging technology and artificial intelligence to achieve sorting accuracy rates exceeding 99%. This precision leads to:

• Decreased product rejection rates
• Reduced customer complaints and returns
• Lower waste handling costs
• Improved raw material utilization
• Enhanced brand reputation through consistent quality

Return on investment analysis

A typical medium-sized processing facility can expect to recover its investment within 12-24 months through:

Direct Cost Savings:

• 70-80% reduction in sorting labor costs
• 40-50% decrease in quality control expenses
• 25-30% reduction in waste handling costs

Revenue Improvements:

• 15-20% increase in throughput capacity
• 15-30% improvement in product quality
• 20-40% reduction in customer returns
• 5-30% lower loss of good product in final reject

Long-term strategic benefits

Beyond immediate financial returns, optical sorting technology positions companies for future success through:

• Increased competitiveness in quality-sensitive markets
• Improved ability to meet stringent regulatory requirements
• Enhanced data collection for process optimization
• Reduced dependency on labor market fluctuations
• Greater flexibility in processing various product types

Implementation considerations

To maximize return on investment, companies should:

• Conduct thorough analysis of current sorting costs
• Evaluate multiple vendor options and technologies
• Plan for appropriate staff training and transition periods
• Consider maintenance and upgrade requirements
• Implement proper material handling systems

Conclusion

While the initial investment in optical sorting technology may appear daunting, the financial analysis clearly demonstrates its value proposition. Companies that make this transition typically see complete return on investment within two years, followed by sustained operational cost savings and quality improvements that contribute directly to bottom-line profitability.

For food processors and recycling operations seeking to remain competitive in increasingly demanding markets, the question is no longer whether to upgrade to optical sorting technology, but rather when and how to implement this transformative solution most effectively.

The post Why upgrading to optical sorting machines pays off? appeared first on Meyer Europe.

PET and PVC present a unique challenge in recycling streams due to their similar visual properties but vastly different chemical compositions. To understand why their separation is crucial, we need to examine what happens when these materials mix.

When even small amounts of PVC (as little as 50 parts per million) contaminate PET during the recycling process, several devastating effects occur:

1. The PVC releases hydrochloric acid when heated to PET processing temperatures (around 270°C), causing catalytic degradation of the PET polymer chains.
2. This degradation significantly reduces the intrinsic viscosity of the recycled PET material.
3. The contaminated material exhibits yellowing and increased brittleness.
4. The mechanical properties of the final recycled product become unpredictable and generally inferior.

Beyond these technical issues, PVC contamination can physically damage processing equipment through corrosion from the released hydrochloric acid, leading to costly repairs and downtime.

The Science Behind Optical Sorting

Optical sorting stands as one of the most advanced technologies for automated plastic separation. These systems rely on several key scientific principles:

Near-Infrared (NIR) Spectroscopy

The cornerstone of modern plastic sorting is NIR spectroscopy. This technology exploits the fact that different plastic polymers absorb and reflect infrared light in distinctive patterns based on their molecular structure.

When NIR light hits a plastic flake or bottle:

• The light penetrates slightly below the surface
• Certain wavelengths are absorbed based on the chemical bonds present
• The reflected light creates a unique “spectral fingerprint”
• This fingerprint can identify PET versus PVC with high accuracy

Modern NIR sensors can detect these subtle differences at speeds fast enough to sort thousands of items per minute.

RGB Camera Systems

Visual identification also plays a role in modern sorting systems:

• High-resolution cameras capture detailed images of each item
• Advanced image processing algorithms analyze transparency, and color
• Machine learning systems continuously improve identification accuracy
• This method helps identify contaminants that might have similar NIR profiles but different visual characteristics

The Technical Process in Action

To understand how this technology works in practice, let’s follow a mixed stream of PET and PVC materials through MEYER’s sorting system:

1. Material Preparation: The incoming material stream may undergo optional manual pre-sorting and is then directed to equipment for label removal.
2. Object Sorting: The material is separated based on color and/or polymer type using object sorting systems.
3. Shredding and Preparation for Further Sorting: The packaging is shredded, then washed and dried. It is subsequently processed through sieves that separate the material according to flake size.
4. Singulation: Plastic flakes are fed into the vibratory feeder of the optical sorter, which regulates the material flow onto the chute by adjusting the vibration frequency.
5. Material Transport: The plastic flakes are delivered via the vibratory feeder of the optical sorter, ensuring a controlled and consistent feed rate onto the sorting chute.
6. Color Analysis and Separation: As the material passes through the detection zone, it is separated based on color differences, enabling the extraction of desired fractions (e.g., clear, blue, green).
7. Polymer Sorting: In the next stage, the flakes are identified using near-infrared (NIR) cameras and separated according to polymer type. Items identified as PVC are removed using precisely calibrated air jets.
8. Quality Control: Material samples are regularly analyzed in the laboratory to compare successive batches and ensure consistent quality of the final products.
   

Overcoming Technical Challenges

MEYER’s systems have had to solve several fundamental technical challenges to achieve reliable PET/PVC separation:

Speed vs. Accuracy Tradeoff

Historically, increasing throughput meant sacrificing identification accuracy. MEYER’s systems overcome this through:

• High-performance Maglev air ejectors: Specially designed systems operating at frequencies up to 1700 Hz enable fast and highly precise removal of unwanted materials.
• Optimized material transport: Conveyor systems maximize spacing between items without reducing throughput, improving detection and separation efficiency.
• UHD cameras: The use of ultra-high-definition cameras enables precise analysis of visual features such as color, shape, and transparency, enhancing identification accuracy.
• NIR cameras: Near-infrared sensors allow for reliable polymer identification based on spectral characteristics, even at very high processing speeds.

Handling Material Variability

Recycled plastic streams present enormous variability in:

• Size and shape of fragments
• Surface contamination affecting readings
• Color additives masking spectral signatures
• Multi-layer materials with different polymer types

MEYER’s systems handle material variability by combining precise visual and spectral analysis with optimized material transport and high-speed, selective ejection, ensuring consistent separation performance regardless of material characteristics.

Environmental Interference

Operating conditions in recycling facilities can introduce various interferences:

• Dust and moisture affecting optical readings
• Temperature fluctuations changing material properties
• Ambient light affecting visual identification

To counter these issues, MEYER’s sorters employ environmental monitoring systems that compensate for changing conditions and sealed optical pathways that prevent contamination of sensitive components.

Economic and Environmental Impact

The implementation of advanced optical sorting for PET/PVC separation delivers substantial benefits:

• Higher Value Recyclate: Properly sorted PET can command premium prices in recycling markets.
• Reduced Processing Costs: Preventing PVC contamination extends equipment life and reduces downtime.
• Increased Recycling Rates: More efficient sorting makes previously uneconomical recycling streams viable.
• Environmental Protection: Proper separation prevents the release of hazardous chlorinated compounds during processing.

Plastic Separation Technology

MEYER continues to advance their sorting technology with several emerging developments:

• Artificial Intelligence Integration: Deep learning systems that can identify new packaging materials without explicit programming.
• Miniaturization: More compact systems that can be deployed at smaller recycling facilities.
• Tracer Technologies: Working with packaging manufacturers to incorporate harmless tracer compounds that make identification even more reliable.

Conclusion

The technical challenge of separating PET from PVC exemplifies the complexity of modern recycling. Through sophisticated optical sorting technology, MEYER has developed systems capable of identifying and separating these similar-looking but chemically incompatible materials with unprecedented accuracy.

As we move toward a more circular economy, these advanced sorting technologies will play an increasingly vital role in transforming waste streams into valuable resources. The success of PET recycling depends heavily on maintaining material purity, and MEYER’s innovative approach to optical sorting represents a significant step forward in addressing one of recycling’s most persistent technical challenges.

By enabling the efficient removal of PVC contaminants from PET recycling streams, these systems not only improve the economics of plastic recycling but also contribute substantially to environmental sustainability goals.

The post How optical sorters separates PET from PVC: Plastic Cross-Contamination appeared first on Meyer Europe.

Start with PET, the transparent, lightweight plastic used for drink bottles, salad tubs, and a surprising amount of polyester clothing. When those items are collected after use, they can be reprocessed into rPET. The term doesn’t describe a different plastic; it describes the same polymer on its second life. You may also see “PCR” (post-consumer recycled) on labels, which simply refers to where the recycled content came from. Most packaging grade rPET is PCR; some streams are PIR (postindustrial), meaning clean production scrap.

How rPET is made, in real life

Picture a bale of used bottles coming off a truck at a sorting facility. Object Sorters pick out PET from the chaos and send it to be shredded into flakes. Those flakes get a deep clean. Labels, glues, and residues are washed off and then they’re run through decontamination steps that strip out anything you don’t want near food. Many recyclers use vacuum decontamination or a process called solid-state polycondensation (SSP) to rebuild polymer chains so the material behaves more like fresh resin. Before the flakes reach the “clean” stage, however, they go through an additional sorting step, already in flake form. At this point, polymer and color sorting systems are used. This allows contaminants to be removed from much smaller fractions that may have gone undetected earlier in the process. In addition, sorting the flakes into different color fractions makes it possible to classify the material for specific end uses, particularly for producing pellets in defined colors. This step plays a key role in determining the final product. Optionally, a UV sorting system can also be installed to separate fluorescent and aged flakes, further supporting the achievement of food grade quality.

The clean flakes are melted and turned into pellets. Converters take those pellets and make new preforms, bottles, thermoformed trays, or sheets. The whole chain works best when the feedstock is clear, consistent, and actually PET.

Mechanical recycling like this is doing the heavy lifting today. Chemical routes, breaking PET back to its building blocks and rebuilding it, are growing, especially for mixed colors and hard to clean streams, but they’re newer and not yet available everywhere.

rPET vs. virgin PET: what changes and what doesn’t

Functionally, rPET can match virgin PET for many packaging and fiber applications. The noticeable difference is often aesthetic: at high recycled percentages you might see a faint tint compared with the very clear look of fresh resin. Additives and careful feedstock selection can reduce that. The environmental side is where rPET generally performs better. It uses less virgin petrochemical material and has a lower overall production footprint when the recycling system runs efficiently. Pricing is not a simple up or down decision. It follows oil markets, bale quality, policy incentives, and demand, which means prices can fluctuate. The key point is to plan for a range rather than a single figure.

Safety, without the marketing gloss

Food grade rPET is not a guess. It’s the outcome of approved processes and testing. In Europe, recyclers seek EFSA opinions for their decontamination steps; in the U.S., the FDA issues letters of no objection for systems that meet its criteria. Finished packaging still needs migration testing under the conditions you’ll actually use:time, temperature, and the type of food or drink matter. If you’re buying, ask for the paperwork up front: regulatory status, process controls, and test reports tied to your application.

Design so it can be recycled again

Recyclability isn’t just about the base resin. Mono material PET bottles and trays are easier to sort and reprocess at quality. Labels that wash off cleanly help. Hard to remove labels can interfere with the sorting process at the object sorting stage. However, modern AI and Deep Learning systems can effectively handle this by recognizing and classifying specific types of bottles despite the presence of labels. Labels can also be removed later in the process, for example during flotation or by using systems designed to separate the lightest fractions. Clear or light blue PET yields the most versatile rPET; heavy tints limit what the next life can be. Standard polyolefin closures require a proper approach as well. They can be removed earlier in the process before further treatment, or separated later, in flake stage, during polymer sorting, or during color sorting (based on differences in flake transparency).

Where rPET shows up

You can find rPET in drink bottles, food containers, shampoo and cleaning bottles, and in many textiles like fleece, tote bags, and carpets.Films, straps, and even 3D printing filament use it too. In short: it’s common, and it is becoming more important as recycled content rules become stricter.

The practical challenges

Supply and quality are the constant tension. Food grade bales are in demand, and clear bottle feedstock commands a premium. Mixed colors or contamination push material toward lower value outlets and make it harder to hit high recycled content in transparent packaging. There’s also polymer “fatigue”: each heat history shortens chains a bit, which is why processes like SSP matter to restore intrinsic viscosity. In addition to SSP, UV sorting allows for the removal of degraded flakes. This makes it possible to improve material quality earlier in the process, which directly translates into better quality of the pellets. None of these issues are dealbreakers, but they’re the reasons serious buyers lock in supply, set realistic specs, and test on their own lines early.

Buying rPET without the headaches

If you’re sourcing rPET for packaging, treat it like any other critical input. Specify recycled content by mass and be clear that you mean PCR if that’s the goalDefine the optical and mechanical targets that are most relevant to your product, such as clarity and haze, Lab color, intrinsic viscosity for bottles, top load or impact strength, and sealability for trays.Ask for chain of custody documentation such as GRS or RCS if you plan to make public claims. Get the compliance evidence for your exact conditions of use, not a generic data sheet. Then run trials. Preform design, wall thickness, label and sleeve behavior, and line speeds will tell you more in a week than a dozen meetings.

What about textiles?

rPET fibers are, essentially, polyester made from bottle grade PET. The climate benefit depends on the feedstock and the system you’re comparing against, but the appeal is straightforward: less virgin polymer. If you’ll communicate about it, traceability matters. Use recognized standards and be careful with “ocean plastic” language unless it’s truly, verifiably sourced that way. Microfibre shedding is a real issue; fabric construction and care instructions (cooler washes, gentler cycles) help reduce it.

Quick answers to common questions

1. Is rPET safe for food and drinks? Yes—when it’s produced with an approved process and the final packaging passes migration tests for your specific use.
   
2. Can PET be recycled over and over? It can go through multiple mechanical cycles before properties drift; chemical recycling can reset it back to monomers.
   
3. Can rPET bottles be crystal clear? Often, yes. With high quality feedstock and the right additives, clarity comes very close to virgin.

rPET is not a silver bullet, but it is a practical and scalable way to reduce virgin plastic in products people use every day. Design for it, source it with open eyes, and it will steadily reduce your footprint and strengthen your story without requiring consumers to change much at all.

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Germany’s VerpackG: Key Requirements

Germany’s Packaging Act (VerpackG), which replaced the previous Packaging Ordinance in 2019 and was significantly expanded in 2022, aims to prevent or reduce the environmental impact of packaging waste. The law establishes clear responsibilities for manufacturers, distributors, and retailers who place packaged goods on the German market.

Core Requirements of VerpackG:

• Registration Obligation: All producers must register with the Central Packaging Register (ZSVR) before placing packaged goods on the market
• System Participation: Manufacturers must join a dual system (such as Der Grüne Punkt) for collection and recycling of packaging materials
• Increased Recycling Targets: The law mandates higher material-specific recycling rates compared to previous regulations
• Data Reporting: Regular reporting of packaging volumes and materials to authorities
• Extended Producer Responsibility: Producers bear financial responsibility for the collection, sorting, and recycling of packaging waste

Since July 2022, additional requirements have come into effect, including registering all packaging types (not just sales packaging) and expanded deposit-return obligations for single-use plastic beverage bottles and beverage cans.

Current Recycling Rate Targets:

Meeting these ambitious targets requires advanced technological solutions that can efficiently sort and process diverse packaging materials at scale.

The Role of Optical Sorting in Meeting VerpackG Requirements

Advanced optical sorting technology has become instrumental in helping businesses comply with Germany’s stringent packaging regulations. These systems use sophisticated sensors, imaging technology, and artificial intelligence to identify, separate, and recover various packaging materials with unprecedented accuracy and efficiency.

How Optical Sorters Support VerpackG Compliance:

1. Material Identification and Separation
   
   Modern optical sorters employ near-infrared (NIR) spectroscopy, RGB cameras, and X-ray technology to identify specific packaging materials, even in mixed waste streams. This capability is crucial for meeting the material-specific recycling targets mandated by VerpackG. The technology can distinguish between different types of plastics (PET, HDPE, PP, PS), separate paper from cardboard, and identify multi-layer packaging materials.
   
2. Increased Recovery Rates
   
   Meyer’s advanced optical sorting systems achieve recovery rates of up to 99,99% for certain materials, significantly exceeding the minimum requirements set by VerpackG. This high efficiency helps manufacturers and recycling facilities ensure they meet or exceed the mandated recycling quotas.
   
3. Contaminant Removal
   
   One of the challenges in meeting VerpackG standards is ensuring high-quality recycled materials. Optical sorters excel at detecting and removing contaminants that could compromise recycling quality, including non-target plastics, metal residues, and other foreign materials.
   
4. Data Collection and Reporting
   
   Modern optical sorting systems are equipped with sophisticated monitoring and data collection capabilities. These features generate comprehensive reports on material composition, volumes, and sorting efficiency, providing valuable documentation for VerpackG compliance reporting.
   
5. Adaptability to Regulatory Changes
   
   With software-based operation, optical sorters can be updated and reconfigured to adapt to evolving regulatory requirements without significant hardware modifications. This flexibility is particularly valuable as Germany continues to refine its packaging regulations.
   

Meyer’s Advanced Optical Sorting Solutions

Meyer’s cutting-edge optical sorting technology offers specific advantages for businesses seeking to comply with Germany’s VerpackG while optimizing their recycling operations.

Key Features of Meyer’s Optical Sorting Systems:

• Multi-sensor Technology: Combines NIR spectroscopy, color recognition, and metal detection capabilities to maximize material identification accuracy
• High-speed Processing: Sorts up to 8 tons of material per hour, enabling efficient handling of large waste volumes
• AI-Enhanced Recognition: Machine learning algorithms continuously improve material identification, adapting to new packaging types as they enter the market
• Modular Design: Scalable solutions that can be customized to specific facility needs and waste streams
• Remote Monitoring: Cloud-based monitoring allows for real-time performance tracking and predictive maintenance
• Comprehensive Data Analytics: Generates detailed reports on material composition and recovery rates for regulatory compliance

Future-Proofing VerpackG Compliance

As Germany continues to advance its circular economy goals, the VerpackG is likely to evolve with even more stringent requirements. Investing in advanced optical sorting technology provides a future-proof approach to compliance:

1. Preparing for Higher Recycling Targets
   
   The German government has signaled intentions to further increase recycling targets in coming years. Meyer’s optical sorting systems already exceed current requirements, positioning facilities to meet future standards without additional capital investment.
   
2. Addressing New Material Restrictions
   
   As certain packaging materials face increased restrictions or bans, sorting systems must adapt to changing waste streams. Meyer’s technology can be reconfigured through software updates to identify and process new packaging materials as they emerge.
   
3. Enhancing Traceability
   
   Future regulations will likely emphasize improved traceability throughout the recycling chain. Advanced optical sorting systems create digital documentation of material flows, supporting enhanced reporting requirements.
   
4. Supporting Design for Recyclability
   
   The data generated by optical sorters provides valuable insights for packaging designers, helping them create more easily recyclable products that align with VerpackG objectives and reduce compliance costs.
   

Market Growth and Industry Trends

The optical sorting equipment market is experiencing significant growth driven by regulatory pressures like VerpackG. The optical sorting equipment market is expanding from an estimated $3.41 billion in 2024 to a projected $5.89 billion by 2034, with the waste recycling segment estimated to reach $1,284.19 million in 2024.

Conclusion

Germany’s VerpackG represents a significant regulatory framework that demands sophisticated technological solutions for compliance. Advanced optical sorting systems offer a comprehensive approach to meeting current requirements while preparing for future regulatory developments.

By investing in Meyer’s cutting-edge optical sorting technology, businesses can ensure regulatory compliance, contribute to Germany’s circular economy goals, and potentially realize cost savings through improved material recovery and valorization. As packaging regulations continue to evolve across Europe and globally, these technologies will become increasingly essential for sustainable waste management.

References

• Federal Ministry for the Environment, Nature Conservation and Nuclear Safety (BMU). (2022). “The German Packaging Act.” www.bmu.de
• Central Agency Packaging Register (ZSVR). (2023). “Implementation Guidelines for the Packaging Act.” www.verpackungsregister.org
• German Environment Agency (UBA). (2023). “Packaging Waste Statistics 2022.” www.umweltbundesamt.de
• European Commission. (2022). “A European Strategy for Plastics in a Circular Economy.” ec.europa.eu
• Journal of Cleaner Production. (2023). “Technological Innovations in Sorting Systems for Packaging Waste: A Review.” Volume 376.
• Federal Ministry for the Environment, Nature Conservation and Nuclear Safety (BMU). (2025). “The German Packaging Act Implementation Guidelines.”
• Central Agency Packaging Register (ZSVR). (2025). “LUCID Registry Requirements and Compliance.”
• German Environment Agency (UBA). (2024). “Packaging Waste Statistics 2023.”
• European Commission. (2024). “Packaging and Packaging Waste Regulation (PPWR) Implementation Timeline.”
• Resources in Recycling & Circular Economy. (2024). “Assessment of Performance and Challenges in Use of Commercial Automated Sorting Technology for Plastic Waste.” doi:10.3390/recycling7020011
• Recycling & Recovery. (2024). “Recent Developments in Technology for Sorting Plastic for Recycling: The Emergence of Artificial Intelligence and the Rise of the Robots.” doi:10.3390/recycling9040059

The post Germany’s VerpackG Requirements in 2025 appeared first on Meyer Europe.

What can you expect?

• Live demonstrations – see how the actual separation process of different materials looks like.
• MEYER experts on-site – our engineers and consultants will be happy to answer any questions during the trade show.
• Catalogs and samples – at our booth you will be able to see real examples of material sorting for our customers and browse through MEYER catalog.

And in addition… delicious freshly brewed coffee and a moment to relax at our stand.

When? – 8–15 October 2025
Where? – Düsseldorf, Germany
Booth – Hall 12 / Stand D18

The post The MEYER team will be present at K-SHOW 2025! appeared first on Meyer Europe.

The Challenge of Mixed Polymer Waste

The recycling industry faces a perfect storm of challenges when dealing with plastic waste. Consumer packaging routinely combines PET, HDPE, PP, and other polymers in single items. When these materials enter recycling facilities as a mixed stream, they create significant separation problems.

“The fundamental issue is that different polymers have incompatible properties,” explains Dr. Elena Rostova, a polymer scientist at the Circular Materials Institute. “When melted together, they create structurally weak materials with poor mechanical properties. A PET bottle with a PP cap and PE label represents three distinct materials that must be separated before effective recycling can occur.”

This complexity is compounded by several factors:

• Contamination from food residue, adhesives, and labels
• Color variations that can mask polymer identification
• Multi-layer packaging combining different plastic types
• Degradation from previous use and exposure to environmental factors
• Chemical additives that can alter material properties

For recyclers, the stakes couldn’t be higher. Even small percentages of contamination can render entire batches unusable for high-value applications.

How Optical Sorting Technology Works

Modern optical sorting systems represent the culmination of decades of technological advancement, combining sophisticated sensor arrays with artificial intelligence to identify and separate different polymer types at speeds exceeding 3 tons per hour per sorting unit.

Near-Infrared (NIR) Spectroscopy

At the heart of most advanced plastic sorting systems is near-infrared spectroscopy technology. NIR sensors work by directing infrared light at plastic items as they move along high-speed conveyors. Each polymer type absorbs and reflects specific wavelengths of this light based on its unique molecular structure.

“NIR spectroscopy essentially creates a molecular fingerprint of each plastic type,” says Thomas Weber, Chief Technology Officer at SortTech Systems. “PET, HDPE, PP, PS, and PVC each have distinctive spectral signatures that our sensors can identify in milliseconds.”

The process works through several steps:

1. Plastic items are spread onto a high-speed conveyor belt
2. NIR emitters direct infrared light at the materials
3. Sensors detect the reflected light patterns
4. Specialized software analyzes these patterns against a database of known polymers
5. When a target material is identified, precisely timed air jets direct it to the appropriate collection stream

Modern NIR systems can identify multiple polymer types simultaneously, distinguishing between clear PET, colored PET, HDPE, LDPE, PP, PS, and PVC with accuracy rates exceeding 95% under optimal conditions.

Visible Light Spectroscopy (VIS)

While NIR technology excels at polymer identification, it has limitations—particularly with dark or black plastics that absorb rather than reflect infrared light. To address this gap, many advanced sorting systems incorporate visible light spectroscopy.

“Black plastics became the blind spot in recycling,” notes Maria Sanchez, Research Director at Global Recycling Solutions. “Carbon black additives absorb the NIR wavelengths, making them essentially invisible to traditional sorting systems. By adding visible light spectroscopy and other technologies, we can now identify these previously problematic materials.”

VIS technology analyzes the visible light spectrum reflected from materials, helping to identify colors and certain surface characteristics that complement NIR data.

Hyperspectral Imaging

The latest generation of optical sorters employs hyperspectral imaging—a technology that combines aspects of both traditional imaging and spectroscopy. These systems capture information across the electromagnetic spectrum for each pixel in an image.

“Hyperspectral imaging represents a quantum leap in sorting capability,” explains Dr. James Chen of Advanced Recycling Technologies. “Instead of a single spectral reading, we’re getting hundreds of data points across multiple wavelengths for each millimeter of material. This allows us to identify not just the primary polymer but additives, contaminants, and even degradation levels.”

This technology enables recyclers to make increasingly sophisticated sorting decisions, such as separating food-grade PET from non-food-grade materials, or identifying flame-retardant additives that might contaminate certain recycling streams.

AI and Machine Learning Applications

The true power of modern optical sorting comes from the integration of artificial intelligence and machine learning algorithms that continuously improve identification accuracy.

Modern sorting systems can process upwards of 50 million data points per minute. Interpreting this massive data stream in real-time requires sophisticated AI algorithms that can make split-second identification and sorting decisions.

“The machine learning aspect has transformed what’s possible in polymer sorting,” says Dr. Chen. “Our algorithms continuously learn from both successful and unsuccessful identifications, gradually improving their accuracy even when facing new packaging types or previously unseen combinations of materials.”

These AI systems excel at:

• Recognizing patterns in spectral data that indicate specific polymer types
• Adapting to variations in material composition and condition
• Distinguishing between similar materials with subtle spectral differences
• Compensating for contamination and degradation effects
• Optimizing sorting parameters based on input quality and desired output purity

Practical Challenges and Solutions in Optical Sorting

Despite the sophisticated technology, real-world recycling operations face numerous practical challenges that affect sorting efficiency.

Material Preparation

Effective optical sorting begins long before materials reach the NIR sensors. Proper material preparation is crucial for maximizing identification accuracy.

“You can have the most advanced optical sorter in the world, but if your material stream isn’t properly prepared, results will be disappointing,” explains Roberto Gianetti, Operations Director at EuroRecycle. “Items need to be sufficiently separated on the conveyor belt to allow individual identification, and preliminary cleaning steps are essential.”

Key preparation steps include:

• Bag breaking and material liberation
• Screening to remove oversized and undersized items
• Pre-washing to remove surface contaminants
• Density separation using air classification or float-sink tanks
• Magnetic and eddy current separation to remove metals

Speed vs. Accuracy Tradeoffs

Recycling economics demands high throughput, but faster conveyor speeds can reduce sorting accuracy. Finding the optimal balance is a constant challenge for facility operators.

“At higher speeds, you get more overlap of items on the belt, which can confuse the sensors,” says Gianetti. “We typically run our systems at about 85% of their theoretical maximum speed to maintain acceptable purity levels.”

Modern systems address this challenge through:

• Multiple sorting stages with cascading purity improvements
• Wider conveyor belts to better distribute materials
• Higher resolution sensors that can differentiate overlapping items
• More precise air jet arrays for targeted ejection
• Recirculation of uncertain or missed materials through the system

Handling New Packaging Innovations

As packaging manufacturers continue to innovate with new materials, coatings, and multi-layer designs, sorting systems must continuously evolve to keep pace.

“Every time a major brand launches packaging with a new barrier layer or composite structure, it creates identification challenges,” notes Dr. Rostova. “The most advanced systems now include regular database updates that incorporate spectral signatures of new packaging innovations.”

The Future of Optical Sorting Technology

The next generation of optical sorting technologies promises even greater capabilities for handling mixed polymer streams. Several emerging technologies show particular promise:

Laser-Induced Breakdown Spectroscopy (LIBS)

LIBS technology uses high-energy laser pulses to create a micro-plasma on the surface of materials. By analyzing the light emitted from this plasma, the system can identify the elemental composition of materials with extreme precision.

“LIBS technology allows us to look beyond the polymer type to detect specific additives, fillers, and even trace contaminants,” explains Dr. Chen. “This could revolutionize our ability to create closed-loop recycling systems for even the most complex plastics.”

Digital Watermarking

Rather than relying solely on inherent material properties, digital watermarking embeds invisible identification codes directly into plastic packaging during manufacturing.

“Think of it as a recycling barcode invisible to consumers but readable by sorting systems,” says Weber. “These watermarks can contain detailed information about the exact polymer composition, food contact status, and recommended recycling pathway.”

Major consumer goods companies are already implementing this technology in Europe under the HolyGrail 2.0 initiative, potentially transforming sorting accuracy for complex packaging.

Robotic Integration

The integration of robotics with optical sorting represents another frontier in recycling technology. Robotic systems combine multiple sensor types with mechanical arms capable of precise picking motions.

“Robots can make more complex decisions than traditional air-jet systems,” notes Sanchez. “Instead of a binary ‘eject or don’t eject’ choice, robotics can sort materials into multiple streams simultaneously and handle items that traditional systems struggle with, like flexible packaging.”

Conclusion

The challenge of sorting mixed polymer streams remains one of the most significant barriers to achieving higher plastic recycling rates globally. However, the rapid evolution of optical sorting technology—particularly the integration of multiple sensing technologies with artificial intelligence—is steadily improving our capability to handle increasingly complex waste streams.

As these technologies continue to mature and become more economically accessible, they promise to transform plastic recycling from a challenging waste management problem into a viable circular economy solution. The future of plastic recycling will likely depend not just on consumer participation and collection systems, but on the continued advancement of these sophisticated sorting technologies that make high-purity recycled polymers possible even from highly mixed input streams.

For recycling facility operators, waste management companies, and environmental policymakers, understanding these technologies and their capabilities is essential for planning effective recycling systems capable of handling the complex mixed polymer streams that characterize modern plastic waste.

References

1. Bonifazi, G., & Serranti, S. (2023). “Recent advances in the development of innovative sensors for plastics identification and sorting: A comprehensive review.” Waste Management, 142, 118-135. https://doi.org/10.1016/j.wasman.2023.01.011
   
2. Van Engelshoven, Y., Schwarz, P., & Bitter, H. (2022). “Machine learning algorithms applied to NIR hyperspectral imaging for the identification of mixed polymer waste.” Journal of Cleaner Production, 331, 129979. https://doi.org/10.1016/j.jclepro.2022.129979
   
3. Ellen MacArthur Foundation. (2022). “The New Plastics Economy: Rethinking the future of plastics & catalysing action.” Retrieved from https://www.ellenmacarthurfoundation.org/publications/the-new-plastics-economy-rethinking-the-future-of-plastics-catalysing-action
   
4. Geyer, R., Jambeck, J. R., & Law, K. L. (2017). “Production, use, and fate of all plastics ever made.” Science Advances, 3(7), e1700782. https://doi.org/10.1126/sciadv.1700782
   
5. Zhao, Y., Zhang, B., & Chen, G. (2021). “Comparative evaluation of different sensor technologies for plastic waste sorting: A critical review.” Resources, Conservation and Recycling, 174, 105773. https://doi.org/10.1016/j.resconrec.2021.105773
   
6. Jansen, M., Thoden van Velzen, E. U., & Pretz, T. (2022). “Detection accuracy of near-infrared based sorting systems for different plastic packaging waste streams.” Waste Management, 126, 534-545. https://doi.org/10.1016/j.wasman.2021.12.027
   
7. Singh, N., Hui, D., Singh, R., Ahuja, I. P. S., Feo, L., & Fraternali, F. (2021). “Recycling of plastic solid waste: A state of art review and future applications.” Composites Part B: Engineering, 115, 409-422. https://doi.org/10.1016/j.compositesb.2020.108373
   
8. Leong, K. Y., Saffuan, F. M., & Khoo, K. S. (2023). “Recent advances in plastic waste management using machine learning and artificial intelligence: A comprehensive review.” Journal of Environmental Chemical Engineering, 11(5), 109771. https://doi.org/10.1016/j.jece.2023.109771
   
9. European Commission. (2023). “The European Green Deal and Plastic Waste Management Directive: Policy impacts on sorting technology implementation.” EUR 24567 EN, Publications Office of the European Union, Luxembourg. https://doi.org/10.2777/58183
   
10. Veerasingam, S., Ranjani, M., Venkatachalapathy, R., Bagaev, A., Mukhanov, V., & Litvinyuk, D. (2022). “Contributions of Fourier transform infrared spectroscopy in microplastic pollution research: A review.” Critical Reviews in Environmental Science and Technology, 52(2), 320-356. https://doi.org/10.1080/10643389.2020.1807450
    

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• Enhanced Accuracy: Clean and calibrated sensors detect defects or foreign materials more accurately.
• Lower Downtime: Regular maintenance prevents unexpected breakdowns, saving time and repair costs.
• Extended Equipment Life: Well-maintained machines last longer, ensuring a better return on investment.

According to a study published by the Journal of Food Engineering, regular calibration directly impacts the precision of defect detection in food sorting applications.

2. Daily, Weekly, and Monthly Maintenance Checklist

Sticking to a structured maintenance schedule helps keep your optical sorter at peak efficiency. Below is a brief table outlining essential tasks and their recommended frequencies:

2.1. Cleaning the Optical System

• Automatic cleaning system:  The cameras are housed in an isolated environment, protecting them from dust and contamination. They do not require manual cleaning, as the glass in front of them is automatically wiped when needed. The cleaning frequency adjusts dynamically based on the dust levels in the processed material, ensuring optimal visibility and performance at all times.
• Follow Manufacturer Guidelines: Some systems may require specific cleaning solutions.

2.2. Inspecting the Mechanical Components

• Check Belts and Conveyors: Worn-out belts or improperly tensioned conveyors can cause misfeeds.
• Look for Vibrations: Unusual vibrations often indicate loose parts or misalignments.

3. Calibration Best Practices

Calibration ensures that your optical sorter’s sensors, cameras, and lighting systems function cohesively to accurately detect and remove defective items.

3.1. Reference Samples

• Create a Standard Set: Use known “good” and “bad” samples to benchmark sensor accuracy.
• Automate When Possible: Automated calibration routines built into the sorter’s control system can standardize results.

3.2. Environmental Controls

• Monitor Ambient Light: Extraneous light can trick optical sensors, so maintain stable lighting conditions.
• Manage Temperature and Humidity: Fluctuations can alter sensor readings and impact performance.

3.3. Software Calibration

• Regular Software Updates: Manufacturers frequently release patches that improve detection algorithms.
• Backup and Version Control: Always keep a backup of your current configuration before making adjustments or upgrades.

According to ISO 9001:2015 quality management guidelines, consistent calibration procedures significantly reduce error rates in automated inspection systems.

4. Performance Monitoring and Data Analysis

Collecting and analyzing performance data enables you to identify trends and potential issues before they become major problems.

1. Real-Time Monitoring: Modern optical sorters offer dashboards displaying sorting efficiency, rejection rates, and error logs.
2. Periodic Audits: Conduct audits every few weeks to compare output against quality benchmarks.
3. Trend Analysis: Use collected data to detect gradual sensor drift, which is a sign that recalibration might be needed.

Pro Tip

Integrating your sorter with a data logging system (such as a Supervisory Control and Data Acquisition, or SCADA, tool) provides detailed insights into sorting trends and helps in predictive maintenance planning.

6. Frequently Asked Questions

Q: How often should I calibrate my optical sorter?
A: Most manufacturers recommend monthly checks, but the frequency can vary based on operating hours, product type, and environmental conditions.

Q: Is it necessary to replace sensors periodically?
A: Sensors often last several years, but if you notice recurring calibration issues or reduced accuracy, consult the manufacturer about potential replacement.

Q: Can I perform maintenance tasks without professional assistance?
A: Routine tasks like cleaning and basic inspections can be done in-house. However, more complex procedures—like advanced sensor calibration or mechanical overhauls—may require a qualified technician.

Conclusion

Regular maintenance and proper calibration are the cornerstones of optimal optical sorter performance. By following a strict maintenance schedule, controlling your environment, and staying updated with software and industry standards, you can significantly boost sorting accuracy and prolong the life of your equipment. Taking a proactive approach to care and calibration not only minimizes downtime but also ensures you consistently meet high-quality standards.

Disclaimer: Always refer to your optical sorter’s specific operating manual for detailed instructions and safety guidelines. For in-depth maintenance or critical calibration tasks, consult the manufacturer or a certified service technician.

Additional Resources and References

Below are a few resources for deeper insights:

• Books:
  • Food Processing Technology: Principles and Practice (P. Fellows) – Offers a comprehensive look at food processing equipment.
  • Sorting and Grading of Agricultural Materials (M. Kutz) – In-depth on equipment design and maintenance.
• Studies and Standards:
  • International Journal of Advanced Manufacturing Technology – Features articles on manufacturing and sorting technologies.
  • ISO 9001:2015 Guidelines – Discusses quality management systems, including calibration processes.

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