Improving Plastic Film Recycling with DATABEYOND FASTSORT-FILM Optical Sorter

Challenges in Plastic Film Recycling

Plastic films such as LDPE wraps, packaging films, and agricultural films are among the most difficult materials to recycle. Their lightweight, flexible nature causes fluttering, entanglement, and unstable trajectories in conventional sorting systems. In mixed waste streams, films often wrap around rollers or sensors, resulting in downtime and high maintenance costs.

Contamination and multilayer structures further complicate the process. Many films contain adhesives, inks, or composite layers like PET/PE, which are hard to separate with standard NIR sorters. As a result, recyclers face low purity, low yield, and poor economics, limiting large-scale recycling of film waste.

The Need for a Specialized Optical Sorting Solution

Traditional optical sorters are mainly designed for rigid plastics. When processing lightweight films, air turbulence and inconsistent reflectance lead to frequent mis-sorting. To achieve efficient recovery of film fractions, the system must ensure stable feeding, precise recognition, and accurate ejection — requirements that standard designs cannot fully meet.

Introducing FASTSORT-FILM by DATABEYOND

To address these challenges, DATABEYOND developed FASTSORT-FILM, an AI-based hyperspectral optical sorter engineered specifically for film and soft plastic recycling.

⭐1. Aerodynamic Design for Lightweight Materials

FASTSORT-FILM adopts an innovative aerodynamic structure with active airflow synchronized to a high-speed belt (3.5–4.2 m/s). This ensures a uniform, spread-out flow of lightweight materials and minimizes turbulence. The optimized collection bin further stabilizes the ejection trajectory, reducing film flotation and drift.

⭐2. AI + SPEC Dual Recognition System

Combining AI machine learning with hyperspectral (SPEC) imaging, FASTSORT-FILM identifies materials by type, polymer, and color with exceptional precision. The dual system accurately distinguishes between similar films — clear PE, tinted PE, or multilayer composites — even under complex conditions.

⭐3. High Accuracy and Throughput

With an applicable size range of 50–300 mm, the system achieves sorting accuracy above 90 %, far surpassing traditional film sorters. Its robust structure prevents mechanical clogging and reduces downtime, ensuring stable and continuous operation.

Benefits for Recycling Plants and MRFs

Higher purity film fractions improve recyclate value.

Lower manual sorting and maintenance costs.

Faster throughput for industrial-scale processing.

Improved ROI through stable performance and yield consistency.

Whether integrated into a mixed waste line or a dedicated film sorting system, FASTSORT-FILM provides a proven path to high-efficiency, high-purity recovery of soft plastic films.

About DATABEYOND

As China’s largest supplier of AI-based optical sorters for recycling front-ends, DATABEYOND has accumulated vast experience across global waste sorting applications. Thousands of its systems operate in Japan, Southeast Asia, Italy, France, Brazil, and Mexico, supporting recyclers in achieving higher recovery and circularity goals.

By combining AI intelligence, hyperspectral imaging, and aerodynamic precision, DATABEYOND continues to redefine how the recycling industry handles complex materials like films and flexible plastics.

If you are seeking a film sorting machine, plastic film recycling solution, or optical film sorter supplier, contact DATABEYOND to learn more about how FASTSORT-FILM can optimize your operation.