Apparatus and methods for preliminary processing of recyclable items in an account-based recycling system

Abstract

Recycling and materials reuse techniques and systems are provided. Bulk deposits of items for recycling or reuse are pre-processed, moving them from one container associated with an account to one or more other containers for handling by a counting system. The one or more containers into which the items are moved are linked to the account. The pre-processing is performed by pre-processing equipment separate from counting equipment in some embodiments.

Description

APPARATUS AND METHODS FOR PRELIMINARY PROCESSING OF RECYCLABLE ITEMS IN AN ACCOUNT-BASED RECYCLING SYSTEMCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application Serial No. 63 / 615,957, filed December 29, 2023 under Attorney Docket No. E0406.70011US00, and entitled “PREPROCESSING STATION,” which is hereby incorporated by reference herein in its entirety.TECHNICAL FIELD

[0002] Aspects of the technology described herein relate to processing techniques and systems for materials recycling or reuse.BACKGROUND

[0003] Some recyclable containers have an associated deposit amount. For example, certain beverage cans and bottles have an associated deposit amount, which in some instances is prescribed by law. The amount is sometimes 5 cents or 10 cents per can or bottle. The consumer pays the deposit when purchasing the beverage bottles / cans at the grocery store and can return the bottles / cans after use to be refunded their deposit. Some recycling systems which refund the deposit on the recyclable bottles / cans are account-based systems. A patron establishes an account with the entity which processes the recyclable bottles / cans. After processing the returned bottles / cans to determine which ones are entitled to a refund, the entity deposits money into the account-holder’s account based on how many bottles / cans the patron returned.BRIEF SUMMARY

[0004] According to an aspect of the technology, a system for processing recyclable items is provided, comprising: a pre-processing station. The pre-processing station is configured to associate a plurality of bulk-deposited recyclable items with an account holder account; analyze the plurality of bulk-deposited recyclable items to assess acceptability for recycling; and output the plurality of bulk-deposited recyclable items. The system for processing recyclable items further comprises a counting station configured to: receive the plurality of bulk-depositeditems pre-processed by the pre-processing station; count the plurality of bulk-deposited recyclable items; and provide a number to a processor.

[0005] Some aspects of the technology provide a system for processing recyclable items comprising: a pre-processing station and a counting station. The pre-processing station is configured to associate a plurality of bulk-deposited recyclable items with an account holder account; analyze the plurality of bulk-deposited recyclable items to assess acceptability for recycling; and output the plurality of bulk-deposited recyclable items. The counting station is configured to receive the plurality of bulk-deposited items pre-processed by the pre-processing station; and scan the plurality of bulk-deposited recyclable items.

[0006] Some aspects of the technology provide a method of processing recyclable items, comprising: receiving at a pre-processing station a first container holding a plurality of bulk- deposited recyclable items; associating the plurality of bulk-deposited recyclable items in the first container with an account holder account; transferring the plurality of bulk-deposited recyclable items from the first container to a second container; analyzing the plurality of bulk- deposited recyclable items to access acceptability for recycling; outputting those of the plurality of bulk-deposited recyclable items associated with the account holder account that are acceptable for recycling without counting; receiving those of the plurality of bulk-deposited recyclable items associated with the account holder account that are acceptable for recycling at a counting station; and scanning those of the plurality of recyclable items associated with the account holder account that are acceptable for recycling.

[0007] Some aspects of the technology provide a system for processing recyclable items, comprising: means for pre-processing a plurality of recyclable items to access acceptability of the plurality of recyclable items without counting the plurality of recyclable items; and a counter configured to count the plurality of recyclable items after operation of the means for preprocessing.BRIEF DESCRIPTION OF DRAWINGS

[0008] Various aspects and embodiments of the application will be described with reference to the following figures. It should be appreciated that the figures are not necessarily drawn to scale. Items appearing in multiple figures are indicated by the same reference number in all the figures in which they appear.

[0009] FIG. 1 illustrates an example of a workflow for handling bulk-deposited recyclable items according to a non-limiting embodiment of the present technology.

[0010] FIG. 2 illustrates an example of various operations that may be performed at the pre-processing station according to a nonlimiting embodiment of the present technology.

[0011] FIG. 3 illustrates an example of various operations that may be performed to assign an account holder account to at least one tray according to a nonlimiting embodiment of the present technology.

[0012] FIG. 4A illustrates an example of an account holder account being linked to a bundle ID according to a nonlimiting embodiment of the present technology.

[0013] FIG. 4B illustrates an example of a quality check being performed on an empty tray according to a nonlimiting embodiment of the present technology.

[0014] FIG. 4C illustrates an example of both a bundle ID and a tray ID being linked to the same account holder account according to a nonlimiting embodiment of the present technology.

[0015] FIG. 4D illustrates an example of a tray ID and an account ID link being severed according to a nonlimiting embodiment of the present technology.

[0016] FIG. 5 illustrates an example of a workflow for flexible processing downstream of a pre-processing station according to a nonlimiting embodiment of the present technology.

[0017] FIG. 6 illustrates a system and dataflow related to a pre-processing station for handling bulk-deposited recyclable items, according to a nonlimiting embodiment of the present technology.DETAILED DESCRIPTION

[0018] In some jurisdictions, bottles and cans have associated deposit amounts which are owed the patron when they return the bottles and cans for recycling. When returned, the bottles and can are counted, and the amount of money owed the patron is determined.

[0019] One system for determining the amount owed to a patron is to use a so-called “reverse vending machines”. The patron inserts their recyclable bottles and cans one-at-a-time into the reverse vending machine. The reverse vending machine determines the amount of the deposit associated with each and returns a credit slip to the patron identifying the total monetary value owed to the patron. The patron may redeem the credit slip at approved locations. The reverse vending machine also crushes the bottles and cans.

[0020] Reverse vending machines suffer several drawbacks. They are inefficient, as each item to be recycled is individually fed into the machine. This alone can take significant patron time, leading to frustration. Moreover, reverse vending machines are often unavailable for use. They fill up quickly with bottles and cans and will not accept further bottles or cans until anauthorized individual empties them. Moreover, they are susceptible to breaking, and frequently require maintenance, either due to patron misuse or normal wear and tear. Such unavailability of the reverse vending machine can further lead to a poor patron experience. Moreover, reverse vending machines can be dirty, unsanitary, and have an odor due to the cans and bottles not being fully emptied and dried prior to insertion. Thus, although reverse vending machines were created to incentivize recycling, such drawbacks of these systems dissuade patrons from using them.

[0021] Another approach to recycling bottles and cans and determining a deposit amount (or other form of remuneration, such as a coupon, contest, acknowledgement, or other incentive) to be refunded to the patron is using an account-based recycling approach, in which the patron deposits the recyclable bottles and cans in bulk, and then the recyclable items are counted later by a processing entity without the involvement of the patron. A patron first establishes an account with the entity that will process the recyclable items. Then, the patron bundles together their recyclable items, for example in a bag, crate, tote, or other container, and deposits them with the recycler or other processing entity. The patron deposits their recyclable items in a manner allowing for them to be associated with the account. For instance, the bag or other container deposited by the patron may bear an identifier of the account holder’s account. The bottles and cans are counted later by the processing entity at a processing facility and associated with the account holder’s account, which is preferable for patrons since it saves them the time of having to wait for their recyclable items to be counted. The account holder’s account is credited for an amount of money corresponding to the recyclable items deposited.

[0022] At an account-based processing facility, items received for recycling are delivered on an irregular basis and in irregular amounts. The items may arrive at the processing facility by truck or other carrier. They may have been collected from various locations at which patrons drop off the recyclable items, such as from grocery stores or remote drop-off locations. Thus, the trucks (or other carriers) may arrive at the processing facility at various times depending on routes, traffic, and schedules for collecting items from the drop-off locations. The amount of recyclable items in the trucks may depend on several factors impacting patron activity, such as time of year, holiday schedules, and weather, among others.

[0023] When the recyclable items arrive at the processing facility (e.g., by truck), an operator unloads them, may optionally allocate them to the account holder’s account, and loads them into a processing station. For example, the operator may unload the bags of recyclable items from the truck onto carts that can be wheeled to the processing station. The operator may allocate the recyclable items in a given bag (or other container) to a particular account holderaccount by scanning at the processing station, a unique barcode, RFID tag, or other identifier provided with the bundle of items. The operator may then load the recyclable items into the processing station. During the loading process, various quality checks are performed to prepare items for processing. These checks include but are not limited to assessing the status of the account holder’s account, checking that the number of items is consistent with the historical data of the account holder account (e.g., the number of items does not exceed limits based on the account holder’s history), removing trash and other unrecyclable or inappropriate items, and removing oversize items.

[0024] Counting stations are used to perform the counting of the bulk-deposited bottles and cans at the processing facility. There are multiple types of counting stations, also known as processing stations, in use at present for counting and identifying returned items. Bulk sorting stations are one form of counting station, and are capable of rapidly sorting and counting large numbers of recyclable items. The counting stations may include machines and human operators. The machines may include, for example, equipment which arranges the bottles and cans in an ordered manner, such as in a single stream, and scans a barcode or other identifier on the bottles and cans. The human operator may perform such functions as removing the recyclable items from the container in which they were bulk-deposited by the patron, allocating them to the account holder’s account, and loading them into the processing station. The processing station then scans the individual returned items for counting / identification (both for crediting the account holder and for billing the distributor and / or disposition). These stations can operate far faster than one or more human operators can currently load the station. For example, some bulk sorting stations can process more than three times the number of items that operators can presently load into the station.

[0025] The inventors have appreciated that counting systems for counting items to be recycled often offer high throughput capability that is not fully realized because of preprocessing activities that are performed as part of the counting process. For instance, the activities performed by the human operator such as those activities described above take time and typically occur more slowly than the machinery operates in counting the items. The time it takes operators to move bundles of recyclable items to the processing station, unload bundles into the machine, and wait for items to process gates the speed of the counting / identification activity. This may result in a ‘feast or famine’ situation as delivery of items for recycling / reuse may be erratic. There may be periods when there is nothing to process and periods that cause backlogs of recycling items to develop, leading to less than maximum efficiency of the recycling system.

[0026] The inventors have further appreciated that increased efficiency may be achieved by providing a separate pre-processing station for performing activities associated with preparing bulk-deposited recyclable items for counting. By separating pre-processing activities from processing activities, the pre-processing stations can be scaled to accommodate peak delivery volumes without the need to scale up the processing station, which currently is underutilized from a throughput perspective.

[0027] The pre-processing station allows items returned for recycling / reuse to be prepared for processing as they are received so that they can later be loaded quickly and efficiently into the processing station. During pre-processing, items can be moved from the bundles (e.g., a first container such as a bag, box, or other collection container) in which they are received, scanned for attribution to the account holder (for crediting), and loaded into a second container (e.g., a tray) with unique IDs (for example, rigid trays with RFIDs) that can be mapped to the account holder. An example of this second container is a tray, which is referred to throughout for simplicity, although other types of containers may alternatively be used. These trays can be loaded in a manner ideally suited for the processing station. The pre-processed trays can then be stored in rolling carts or placed on conveyors (or other transport mechanisms) so they can be moved to a holding area and staged for later processing. The later processing may occur soon after pre-processing (e.g., within minutes or immediately after pre-processing), or much later (e.g., hours or days later). Thus, the pre-processed trays can be stored for a period up to days, weeks, or months after pre-processing to accommodate, for example, large deliveries, to queue for sufficient backlog, and / or wait for maintenance to be performed on processing equipment, for example. This ability to conclude pre-processing activities and store the recyclable items for later processing without the need to pre-process them again may ensure greater efficiency for processing items for recycling. When applicable, the pre-processed trays can be easily moved via cart or conveyor to the processing station for processing at a suitable time based on item volume, operator availability, and processing capacity. The pre-processing station is, in some embodiments, an optical station that can run a series of filters to perform quality checks and control the process of loading items into trays.

[0028] The pre-processing station introduces greater efficiency for processing items for recycling by allowing materials to be prepared for processing at a work area separate from the processing station. Pre-processing activities may be performed by human operators and / or machines to output a plurality of recyclable items already evaluated for acceptable input to the counting system and already associated with the account holder account. Pre-processing allows the quality checks currently performed at processing stations to be performed prior to delivery ofitems to the processing station. Pre-processed materials, stored in uniquely identified trays, can then be held in a staging area until a suitable time for processing. Pre-processed items can then later be efficiently loaded onto the processing station for processing.

[0029] The pre-processing station allows returned items to be efficiently prepared for later counting / identification. By removing operator pre-processing activities from the processing station, the present technology allows the counting / identification station to run at quicker speeds and prevents backlogs at this station. Use of the pre-processing station also results in a reduction of operator labor needed at the processing station and allows greater opportunity to balance the workload in the processing facility (e.g., factory). Pre-processing can be scaled as needed so that item deliveries can be unloaded and preprocessed on demand and then processing can be performed very quickly during times between deliveries, allowing flexible deployment of operators between the two types of workstations. The pre-processing station also supports flexible processing downstream of the pre-processing station. For example, material can be routed to different processing lanes based on the characteristics of the items or information about the account or account holder.

[0030] In contrast to approaches focusing on marginal improvements to the efficiency of operators, the pre-processing station separates the labor-intensive phase of preparing items for counting / identification from the counting / identification process, which can be highly automated on its own. In this way, the pre-processing station provides far greater throughput improvements and a potential reduction in overall labor needs.

[0031] To realize the benefits of an automated process for identifying and / or counting bulk-deposited items for recycling in an account-based recycling facility (e.g., factory), aspects of the present technology perform pre-processing of the items such that operator involvement in loading the machinery for the identification / counting stage is reduced or eliminated. The preprocessing station according to aspects of the present technology allows items returned for recycling to be prepared for counting / identification as they are received at the processing facility so that they can later be loaded into processing stations efficiently and in less time than if the pre-processing activities were combined with the processing station.

[0032] The aspects and embodiments described above, as well as additional aspects and embodiments, are described further below. These aspects and / or embodiments may be used individually, all together, or in any combination of two or more, as the application is not limited in this respect. For simplicity of explanation, the following description makes explicit reference to recycling systems and materials for recycling. However, the features described apply equally to systems for processing materials for reuse other than recycling.

[0033] FIG. 1 illustrates an example of a workflow 100 for handling bulk-deposited recyclable items according to a non-limiting embodiment of the present application. The bulk- deposited items may be delivered to a processing facility in a vehicle 102, such as a truck, in the form of bundles 104 containing recyclable items. The bundles 104 may be in the form of bags, boxes, and / or totes. For simplicity of explanation, the bundles are sometimes referred to herein as being bags, although it should be appreciated that each such reference equally refers to boxes or totes unless the context clearly conveys otherwise. In some embodiments, the bundles are opened and the recyclable items from the bag placed in a tray 106 for input to the pre-processing machinery 108. Separate pre-processing and counting stations may be provided according to aspects of the present technology. The tray 106 may pass through the pre-processing machinery 108 which may perform the various activities described above (and also further below) in connection with pre-processing. The output from the pre-processing station is a tray 106 of recyclable items prepared for counting / identification. Such counting / identification may be performed soon after the pre-processing in some embodiments. The tray 106 may optionally be stored in other embodiments, for instance, on a rack 110 and later delivered to the processing station 112 for a period up to days, weeks, or months after pre-processing.

[0034] The processing station 112, also known as the counting station, may perform activities sufficient to put the bulk-deposited recyclable items in a state for counting. For example, the processing station may arrange the recyclable items in a single-file line or other order which facilitates analyzing the recyclable items. The processing station may orient the recyclable items in an appropriate orientation to facilitate analysis.

[0035] The counting station may then operate to count the items and / or determine the amount of money (or other form of remuneration) to refund the account holder. For example, the counting station may scan the items with a suitable scanner, such as a barcode scanner to scan a barcode on the recyclable items. The processing station may generate a count number representing the number of recyclable items and the amount to refund the account holder may be determined from the count number. As an example, the amount to refund the account holder may be determined by supplying the count number to a processor, which may multiply the count number by the deposit amount associated with each recyclable item. Alternatively, the deposit amount of each recyclable item may be determined at the counting station and the amounts added together. Irrespective of how the amount to refund the account holder is determined, a credit to the account holder’s account may be made based on the result of the counting operation.

[0036] FIG. 2 illustrates an example of a pre-processing station configured to record contents of a tray according to a nonlimiting embodiment of the present technology. In some embodiments a pre-processing station 200 may have a conveyor 202 configured to move a tray 204 from a first end 206 of the conveyor 202 to a second end 208 of the conveyor 202. A tray feeder 210 may be located at the first end 206 of the conveyor 202. The tray feeder 210 may accept a tray 204, for example, from an operator, robot, or additional conveyor separate from conveyor 202. A tray exit 212 may be located at the second end 208 of the conveyor 202. The tray exit 212 may allow a tray 204 to be transported from the pre-processing station 200 to a processing station. The tray exit 212 may alternatively or additionally allow a tray 204 to be transported from the pre-processing station 200 to a storage location. A tray 204 may be transported to a processing station or storage location, for example, by an operator, robot, rolling rack, or additional conveyor separate from conveyor 202. The pre-processing station 200 may have gates 214 configured to control the flow of trays 204 from the first end 206 of the conveyor 202 to the second end 208 of the conveyor 202. If alternative forms of moving the trays are used, other than conveyors, then other mechanisms may be used to control the flow of trays as appropriate. The pre-processing station may have a power input (not shown) to provide electrical service for running the pre-processing station.

[0037] The pre-processing station 200 may have a plurality of scanners. In some embodiments, the pre-processing station 200 may have a bundle scanner 216 to read a bundle ID associated with an account holder’s account. In some embodiments, the pre-processing station 200 may have a tray scanner 218 to read a tray ID of tray 204. The tray ID of tray 204, for example, may be temporarily linked to an account holder’s account as will be described in connection with FIGs. 4C-4D of the present disclosure.

[0038] The pre-processing station 200 may have at least one camera 220 configured to capture an image of recyclable items in a tray 204. In some embodiments the at least one camera 220 may be an infrared camera or visible-light camera. In some embodiments the at least one camera 220 may be a low-resolution camera or a high-resolution camera. An image captured by the at least one camera may be used to create a photographic record of recyclable items (processed material and rejected material) in a tray 204 in the event there is a need for later follow-up with the account holder, for example. In a further example, container IDs (e.g., of recyclable items such as cans and bottles) may be extracted from the photographic record of the recyclable items to later count the recyclable items and credit the account holder’s account for an amount of money corresponding to the number of recyclable items deposited.

[0039] The pre-processing station 200 may have a plurality of sensors 222. In some embodiments, at least one of the plurality of sensors 222 may be an optical sensor. In some embodiments, at least one of the plurality of sensors may be a thermal sensor. In some embodiments, at least one of the plurality of sensors 222 may be a motion detector sensor. The plurality of sensors 222 individually and / or collectively may be configured to assess the acceptability of the recyclable items for recycling.

[0040] Alternatively, or additionally, a display 224 may provide feedback to an operator based on input received from the plurality of sensors 222. For example, at least one of the plurality of sensors 222 may detect that the tray 204 is in an incorrect position and provide feedback to the operator on the display 224 to correct the position of tray 204. In a further example, at least one of the plurality of sensors 222 may detect an issue where the tray 204 has unwanted debris or excessive moisture. In this example, feedback may be provided to the operator on a display 224 indicating the debris and moisture should be removed from tray 204. In yet a further example, at least one of the plurality of sensors 222 may detect the types of materials in the tray 204. In this example, feedback may be provided to the operator on a display 224 that indicates a specific processing station to which this tray should be transported.

[0041] The pre-processing station 200 may have a computer 226. In some embodiments the computer 226 may be configured to operate the pre-processing station 200 by implementing business logic. Business logic may be the performance of steps or ordering of steps selected to comply with business policies or objectives. For example, different patrons of the recycling system may have different objectives or needs, and likewise the recycling operator may want to perform different processing based on the nature of the patron. For example, different processes may be implemented when processing recyclable items from restaurants than from individual patrons. The business logic may be targeted to optimizing accuracy, data reporting capabilities, speed, efficiency, safety of the processing facility and workers in the facility, or resource availability, among other possible objectives. Business logic may thus dictate or lead to instructions for customizing the pre-processing station 200. For example, the computer may implement at least one quality check. In a further example, the computer 226 may provide feedback to the operator on the display 224. In a further example, the computer may control gates 214 to regulate the flow of trays 204 from the first end 206 of the conveyor 202 to the second end 208 of the conveyor 202. In a further example, the computer 226 may regulate the arrangement of cameras 200 and sensors 222 used in a pre-processing station 220. In yet other embodiments, the computer 226 may receive data from systems and transmit data to systems. For example, the computer 226 may receive data from an account management system thatmanages account holder accounts and may transmit data to the account management system. In a further example, the computer 226 may receive data from a factory control system and may transmit data to the factory control system.

[0042] The pre-processing station 200 may have lighting components. In some embodiments the pre-processing station 200 may have signal lights 228. For example, the signal lights 228 may be used to alert an operator if an error occurs during a quality check. In a further example, the signal lights 228 may be used to guide an operator’s actions such as indicating a tray 204 is ready to be routed to a processing station. In some embodiments, the pre-processing station 200 may have overhead lights 230. The overhead lights 230, may be used, for example, to illuminate the pre-processing station 200, allowing an operator to view and perform preprocessing activities.

[0043] FIG. 3 illustrates a method 300 that may be performed at a pre-processing station (e.g., pre-processing station 200 of FIG. 2) according to a nonlimiting embodiment of the present technology. In some embodiments, an empty tray may be loaded into the pre-processing station at step 302. For example, as further described above in connection with FIG. 2, the empty tray may be loaded at the first end of the conveyor. A quality check may be performed on the empty tray at step 304. For example, as further described below in connection with FIG. 4B, this quality check may involve verifying the empty tray is available for use. A quality check may be performed on the bundle to be loaded into the tray at step 306. For example, as further described below in connection with FIG. 4C, this quality check may involve determining an appropriate pre-processing lane for the bundle and / or verifying the validity of the bundle ID. The recyclable items may be loaded from the bundle into the tray at step 308. For example, if the bundle is a bag, the recyclable items from the bag may be emptied into the tray. The tray may be temporarily assigned to an account at step 310. For example, as further described below in connection with FIG. 4C, both a tray ID and bundle ID may be linked to an account ID for a given account holder. The account ID may uniquely identify the account. Alternatively, the tray ID may simply be linked to the bundle ID and the account ID may be omitted from the preprocessing. For example, in alternative embodiments the account ID may be captured prior to or at the time a patron drops off recyclable items, and that information may be stored by the account management system for later use, thus obviating the use of the account ID during preprocessing operations.

[0044] The contents of the tray may be recorded by a plurality of sensors and cameras at step 312. For example, as described above in connection with FIG. 2, at least one camera and at least one other sensor may collect data from the contents of the loaded tray. A quality check maybe performed on the contents of the tray at step 314. For example, as further described below in connection with FIG. 5, this quality check may involve verifying inappropriate items have been removed from the tray, such as trash, hazardous items, or other non-recyclable / reusable items. The tray may be transported to the appropriate processing stage at step 316. For example, the loaded tray may be routed from the second end of the pre-processing station to the appropriate processing station.

[0045] FIGS. 4A - 4D illustrate examples of operations that may be performed to assign an account to at least one tray according to a nonlimiting embodiment of the present technology.

[0046] FIG. 4A illustrates an example of an account being linked to a bundle ID according to a nonlimiting embodiment of the present technology. In some embodiments, a bundle 400 may be assigned a unique bundle ID 402. The unique bundle ID 402 may be, for example, a barcode, QR code, or RFID tag. For example, the bundle ID 402 may be linked in an account management system 416 to the account holder’s account using their account ID 404, which may uniquely identify the account. Items for recycling in the bundle 400 are assigned to the account holder’s account for reimbursement. The account ID may be a sequence of at least one letter and / or at least one number. The account ID may not include any personally identifiable information about the account holder or otherwise. In some embodiments, more than one bundle ID 402 may be linked in the account management system to the same account ID 404. Information about the account associated with the account ID 404 may be determined by, for example, querying an account management system (e.g., in the Cloud), or from a local system if such a system stores characteristics of accounts. In some embodiments, a quality check may be performed on the account associated with the account ID 404 before bundle ID 402 is linked to the account ID 404. A check for fraudulent accounts and deactivated accounts can be performed at the pre-processing station instead of during item counting / identification of the processing station, for example. In some embodiments, verification that bundle ID 402 is successfully linked to account ID 404 may be shown on a display 414 for an operator located at the pre-processing station or another point within the processing facility. Alternatively, the information may be displayed to a remote operator.

[0047] FIG. 4B illustrates an example of a quality check being performed on an empty tray according to a nonlimiting embodiment of the present application. In some embodiments an operator may manually perform a quality check. Alternatively, or additionally, the preprocessing station may automatically perform a quality check.

[0048] At least one quality check may be performed on an empty tray. A quality check may be used to verify that a tray 406 is available for use. As shown in FIG. 4B, a tray 406 is loaded into the pre-processing station 408. A piece of trash 410 is inside tray 406. In some embodiments, a message 412 on a display 414 may indicate an error condition in that the tray 406 is not empty and is not currently available for use. Once the piece of trash 410 is removed from tray 406, the message 412 on display 414 may indicate the tray 406 is available for use.

[0049] Further or alternative quality checks may be performed compared to the quality check shown in FIG. 4B. For example, a quality check may be performed to see if the tray ID is in the correct position to be scanned by a tray scanner. If not, a message may be generated for an operator, and the operator may adjust the tray to correct its position or orientation. In a further example, a quality check may be performed to see if the tray ID is already linked to an account holder account from a previous transaction (e.g., a previous use of the tray within the preprocessing station). If the tray ID is already linked to an account, this link must be severed before the tray may be used in the pre-processing station for processing the current bundle of recyclable items. In yet a further example, a quality check may be performed to see if the tray is in service and is labeled with a tray ID.

[0050] FIG. 4C illustrates an example of both a bundle ID and a tray ID being linked to the same account according to a nonlimiting embodiment of the present application. In some embodiments tray ID 414 may be a barcode, QR code, or RFID tag. In some embodiments, more than one tray ID 414 may be linked in the account management system to the same account ID 404. For ease of processing, the pre-processing station can support splitting of items into multiple uniquely identified trays and ensure that the items in all the trays are attributed to the same account. As shown in FIG. 4C, a tray 406 is loaded into the pre-processing station 408. Recyclable items 403 from a bundle 400 (no longer in the bag, box, tote, or other container) are placed inside tray 406. In some embodiments an operator may manually scan both the bundle ID 402 and tray ID 414. Alternatively, or additionally, the pre-processing station 408 may automatically scan the bundle ID 402 and tray ID 414. As described above in connection with FIG. 4A, bundle 400 may be linked in the account management system 416 to the account holder’s account using their account ID 404 and the bundle ID 402. Tray 406 may be linked to the same account ID 404 to that to which bundle 400 is linked. In this example, tray ID 414 may be linked to the account ID 404. If the bundle ID has not yet been linked to an account ID 404, both tray ID 414 and bundle ID 402 may be linked to account ID 404. In some embodiments, verification that bundle ID 402 and tray ID 414 are linked to account ID 404 may be shown on a display 414.

[0051] At least one quality check may be performed on bundle 400, the items 403 from the bundle and / or tray 406 at the pre-processing station 408 before linking bundle ID 402 and tray ID 414 to the account 404. For example, account management system 416 may assess the account, for example to assess the status of the account (e.g., verify that the account associated with account ID 404 is valid). Determining the validity of an account may include verifying that the account is active and verifying that the account is not fraudulent. Assessing the account may additionally or alternatively include assessing whether the current transaction is consistent with historical account activity, such as whether the number of recyclable items is within a limit consistent with the historical account activity. In yet a further example, account management system 416 may verify that bundle ID 402 is not a duplicate. In yet a further example, account management system 416 may determine that bundle 400 cannot be identified. In this example, bundle 400 may not have a bundle ID or may not have an acceptable bundle ID that can be verified by the account management system 416.

[0052] In some embodiments, account management system 416 may verify that bundle 400 is appropriate for processing at the pre-processing station 408 before linking bundle ID 402 and tray ID 414 to the account 404. For example, a bundle 400 associated with an account that has been flagged due to the account holder’s historical behavior may be moved to a separate preprocessing station 408 for special, manual handling. In yet a further example, the account holder’s history can be used to help identify items and route them appropriately for disposition. As a result, account holders may be credited earlier for their returned items. Determining the appropriate lane for bundle 400 may depend on the content of bundle 400. As an example, bundle 400 may be moved to a separate pre-processing station 408 used to process oversized items such as 5-gallon water jugs if the recyclable items 403 from the bundle 400 are seen to include such items. Alternatively, bundle 400 may be moved to a separate pre-processing station 408 used to process only aluminum items.

[0053] FIG. 4D illustrates an example of a tray ID and account ID link being severed according to a nonlimiting embodiment of the present application. In some embodiments, after a bundle has been processed at the processing station, the link between the tray associated with the bundle and the account ID must be severed before the tray can be reused in the pre-processing station for a different transaction or bundle. For example, as shown in FIG. 4D, tray 406 is empty after being processed in the processing station. The account management system 416 may sever the link between tray ID 414 and account ID 404. In some embodiments, a message 412 on a display 414 may indicate to an operator that the link has been severed between tray ID 414 and account ID 404, and that tray 406 may be available for use in the pre-processing station.

[0054] FIG. 5 illustrates an example of a workflow for flexible processing downstream of a pre-processing station according to a nonlimiting embodiment of the present technology. The pre-processing station described in connection with FIG. 5 may be of the same type as the pre-processing station described above in connection with FIG. 2. The bulk-deposited recyclable items may be delivered in a vehicle, such as a truck, in the form of bags containing recyclable items, such as bottles and cans. In some embodiments, the bags are opened, and the recyclable items from the bag placed in a tray for input to the pre-processing machinery. The tray may pass through the pre-processing machinery which may perform the various checks described above in connection with pre-processing. The output from the pre-processing station is a tray of recyclable items prepared for counting / identification. Such counting / identification may be performed soon after the pre-processing in some embodiments. The tray 106 may optionally be stored in other embodiments, for instance, on a rack 110 and later delivered to the processing station 112 for a period up to days, weeks, or months after pre-processing.

[0055] In some embodiments, the system can instantiate workflows to perform any number of actions. In particular, at block 502, workflow 500 begins. At block 504, an account may optionally be linked to a bundle ID as discussed above in connection with FIG. 4A. At block 506, the system may automatically perform at least one quality check on an empty tray as discussed above in connection with FIGs. 4B and 4C. Alternatively or additionally, an operator may manually perform the at least one quality check. If the empty tray passes the quality check at block 506 or if it fails the quality check but the cause of failure is corrected at block 510 (“Operator fixes issue), the tray is loaded into the pre-processing station at block 512. At block 514, contents from a bundle may be loaded into the empty tray. At block 516, a tray ID may be linked to the same account as discussed above in connection with block 504 as well as in connection with FIG. 4C.

[0056] In some embodiments, the system can instantiate further quality checks on a loaded tray. In particular, at block 518, the system may automatically perform at least one quality check on the loaded tray. Alternatively, or additionally, an operator may manually perform the at least one quality check. For example, the pre-processing station may record electronic images of the contents of each tray and may use sensors to collect additional data about tray contents. As discussed above in connection with FIG. 2, the pre-processing data may record contents of the loaded trays using at least one camera and at least one sensor. Data from the at least one camera and the at least one sensor may be used to perform the at least one quality check on the loaded tray and may optionally be saved for future analysis, for example in response to account holder requests to reconcile information about the recycled items. Forexample, a quality check may be performed to verify that the contents of the tray are not stacked and that the items lay flat in the tray. In a further example, a quality check may be performed to identify if any inappropriate items (e.g., trash) are present and need to be removed. In yet a further example, a quality check may be performed to identify if there is too much liquid in the tray.

[0057] If the empty tray passes the quality check at block 518 or if it fails the quality check but the cause of failure is corrected at block 522 (“Operator fixes issue”), the tray may subsequently go to one of two alternative processing routes in the workflow 500. The loaded tray may stay at the current lane for processing (e.g., block 524). Alternatively, the loaded tray may be transported to a separate lane (e.g., block 526) for processing depending on the contents of the loaded tray. For example, certain processing lanes may only be used to collect oversized items. In yet a further example, certain processing lanes may be used to separate items for reuse from items for recycling. In yet a further example, some workflows may employ random manual quality checking or auditing, or may flag certain accounts as warranting further investigation, and therefore certain loaded trays may be diverted to a separate lane as part of such an auditing effort.

[0058] Workflow 500 ends at block 528 where the loaded tray may be released and routed for storage at a staging area or for immediate movement to a processing station.

[0059] Flexible processing downstream of a pre-processing station promotes efficiency in workflow 500. For example, if an issue arises during a quality check, the loaded tray can be rerouted to a special handling lane to promote continuous flow of the pre-processing station and prevent a slowdown or a shutdown of the processing station. In a further example, as discussed above in connection with FIG. 4C, an account holder’s history can be used to route trays to the appropriate pre-processing stations. In yet a further example, as discussed above in connection with FIG. 2, using data from the at least one camera and the at least one sensor, the system may determine the appropriate processing lane for the loaded tray. Determining the appropriate preprocessing and processing lanes for loaded trays can reduce the amount of time spent on sorting the items from the bundle. Alternatively, or additionally, multiple pre-processing stations can feed a single processing station, efficiently loading the processing station.

[0060] FIG. 6 illustrates a system and dataflow related to a pre-processing station for handling bulk-deposited recyclable items, according to a non-limiting embodiment of the present technology. The system 600 illustrates three levels of operation: facility management system 602, pre-processing station 606, and production system 622. Facility management system 602 may store data about trays used in the pre-processing operation in tray datastore 604(e.g., a tray data management system), the pre-processing station 606 itself, and a facility management datastore 608. Facility management datastore 608 may store data relating to the appropriate processing station for routing each respective tray. Pre-processing station 606 described herein may be of the same type as the pre-processing station described above in connection with FIG. 2.

[0061] Pre-processing station 606 may implement workflow 610. Workflow 610 begins at block 612. At block 612, trays enter pre-processing station 606. At block 614, contents of the trays are scanned. Block 614 may include, for example, scanning the tray contents, and optionally recording contents of the loaded trays using at least one camera and at least one sensor. At block 616, the containers are processed. Block 616 may include, for example, performing quality checks on trays. At block 618, flexible processing downstream of the preprocessing station is used to determine the appropriate processing station for routing trays. Workflow 610 ends at block 620, where the trays are released and routed to the appropriate station for processing. Production system 622 may store data about the contents of trays in collection datastore 624 used in the pre-processing operation, the pre-processing station 606 itself, and an account datastore 626. Collection datastore 624 may alternatively or additionally store data relating to the appropriate processing station for routing each respective tray. Account datastore 626 may store data regarding quality checks on tray contents. Alternatively, or additionally, account datastore 626 may store data relating to the appropriate processing station for routing each respective tray. Such a data management system described in relation to production system 622 is described, for example, in U.S. Patent 11,037,235, which is owned by the assignee of the present application, and which is incorporated by reference herein in its entirety.

[0062] It should be appreciated that alternative process flows to that illustrated in FIG. 6 are possible and consistent with aspects of the present technology. For example, the process flow may operate to store pre-processing data in the facility management system initially, and then later transfer the data from the facility management system to the production system. This manner of operation may facilitate continued processing of recyclable items even if the connection (e.g., network) between the processing facility and production systems is lost. Thus, for example, the outputs of 614 and 616 may be sent to the facility management system 602 initially, and later transferred from the facility management system 602 to the production system 622. Further alternative processing flows are also possible.

[0063] The pre-processing stations of the types described herein may be located in various manners with respect to processing stations for the recyclable or reusable items. In someembodiments, the pre-processing station may be physically separate from the processing station and may even be geographically separated. For example, the pre-processing station may be located in one building in one location and the processing station may be located in a building at a separate location. In some embodiments, the pre-processing station may be integrated with a processing station facility. For example, the pre-processing station may be situated at the same geographic location as the processing station, but in different portions of a building.

[0064] The control and operation of the pre-processing stations and processing stations may be handled in various manners. The pre-processing station may be operated by one entity and the processing station by another. The pre-processing station equipment and operations may be controlled by one entity, while processing activity may be controlled by a separate entity. The pre-processing station may be a modular solution pluggable into the overall recycling workflow. The pre-processing station may utilize the Internet for at least some of its operations. Alternatively, or additionally, the pre-processing station may operate independently of the Internet and instead may communicate with a central database (not pictured). The central database may include data from tray data management system 604, facility data management system 608, collection data management system 624, and account data management system 626.

[0065] Aspects of the present technology may provide processor-executable methods which may be implemented by one or more processors executing processor-executable instructions. The processor-executable instructions may be stored on a non-transitory storage medium, such as an optical disk, a cd, a tape, a solid-state memory, or any other suitable storage. A processor (e.g., as part of a computing device such as a computer, tablet, or other computing device) may access and execute the processor-executable instructions to perform one or more of the steps described herein. For example, one or more steps of the methods described herein may involve or be performed by a processor executing processor-executable instructions.

[0066] It should be appreciated from the foregoing description that although aspects of the present technology apply to systems in which patrons return recyclable items having associated monetary deposit amounts, not all aspects are limited to operation in such systems. For example, aspects of the present technology apply equally to recycling systems in which recyclable items do not have an associated monetary deposit or patrons are not refunded a monetary amount, but instead in which remuneration for recycling takes the form of coupons, acknowledgement, or other incentives. In such systems in which account holders are provided something other than a monetary amount in exchange for recycling, pre-processing of returned recyclable materials may still be performed according to the aspects of the technology described herein.

[0067] It should also be appreciated that various modifications of the processing operations described herein are possible. For example, as an alternative to those situations described above in which an account ID is captured during pre-processing operations, the account ID instead may be captured at a different point in processing. For example, the account ID may be captured prior to or when a patron returns recyclable items. The account ID may be pulled from an account management system when needed in some embodiments. Thus, it should be appreciated that aspects of the present technology relating to pre-processing of recyclable items may operate without capturing an account ID in at least some embodiments. Instead, for example, linking tray IDs and bundle IDs may be sufficient to perform a desired level of pre-processing.

[0068] The indefinite articles “a” and “an,” as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean “at least one.”

[0069] The phrase “and / or,” as used herein in the specification and in the claims, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and / or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the “and / or” clause, whether related or unrelated to those elements specifically identified.

[0070] As used herein in the specification and in the claims, the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements may optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified.

[0071] Use of ordinal terms such as “first,” “second,” “third,” etc., in the claims to modify a claim element does not by itself connote any priority, precedence, or order of one claim element over another or the temporal order in which acts of a method are performed, but are used merely as labels to distinguish one claim element having a certain name from another element having a same name (but for use of the ordinal term) to distinguish the claim elements.

[0072] The terms “approximately” and “about” may be used to mean within ±20% of a target value in some embodiments, within ±10% of a target value in some embodiments, within±5% of a target value in some embodiments, and yet within ±2% of a target value in some embodiments. The terms “approximately” and “about” may include the target value.

[0073] Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having,” “containing,” “involving,” and variations thereof herein, is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.

[0074] Having described above several aspects of at least one embodiment, it is to be appreciated various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be object of this disclosure. Accordingly, the foregoing description and drawings are by way of example only.

Claims

CLAIMSWhat is claimed is:

1. A system for processing recyclable items, comprising: a pre-processing station configured to: associate a plurality of bulk-deposited recyclable items with an account; analyze the plurality of bulk-deposited recyclable items to assess acceptability for recycling; and output the plurality of bulk-deposited recyclable items; and a counting station configured to: receive the plurality of bulk-deposited items pre-processed by the pre-processing station; and scan the plurality of bulk-deposited recyclable items.

2. The system of claim 1 or any preceding claim, wherein the pre-processing station and the counting station are disposed at separate physical locations.

3. The system of claim 1 or any preceding claim, wherein the pre-processing station is further configured to transfer the plurality of bulk-deposited recyclable items from a first container in which the plurality of bulk-deposited items are received from a patron to a second container for the analysis to assess acceptability for recycling.

4. The system of claim 3 or any preceding claim, wherein the first container is a bag and the second container is a tray.

5. The system of claim 1 or any preceding claim, wherein the pre-processing station comprises an optical sensor configured to assess the acceptability for recycling.

6. The system of claim 1 or any preceding claim, wherein the pre-processing station is further configured to assess the account.

7. The system of claim 6 or any preceding claim, wherein the pre-processing station is configured to assess the account for status.

8. The system of claim 6 or any preceding claim, wherein the pre-processing station is configured to assess the account for consistency with historical account activity.

9. The system of claim 1 or any preceding claim, wherein the pre-processing station comprises a modular collection of equipment configured to perform the functions of the preprocessing station.

10. The system of claim 1 or any preceding claim, wherein the counting station is configured to provide a count number of the recyclable items to a processor.

11. The system of claim 1 or any preceding claim, wherein the counting station is configured to determine a deposit amount to refund an account holder based on scanning the plurality of bulk-deposited recyclable items.

12. A method of processing recyclable items, comprising: receiving at a pre-processing station a first container holding a plurality of bulk- deposited recyclable items; associating the plurality of bulk-deposited recyclable items in the first container with an account; transferring the plurality of bulk-deposited recyclable items from the first container to a second container; analyzing the plurality of bulk-deposited recyclable items to assess acceptability for recycling; outputting those of the plurality of bulk-deposited recyclable items associated with the account that are acceptable for recycling without counting; receiving those of the plurality of bulk-deposited recyclable items associated with the account that are acceptable for recycling at a counting station; and scanning those of the plurality of recyclable items associated with the account that are acceptable for recycling.

13. The method of claim 12 or any preceding claim, wherein the pre-processing station and the counting station are physically separate.

14. The method of claim 12 or any preceding claim, wherein the first container is a bag and the second container is a tray.

15. The method of claim 12 or any preceding claim, wherein analyzing the plurality of bulk- deposited recyclable items to assess acceptability for recycling comprising analyzing the plurality of bulk-deposited recyclable materials using an optical sensor.

16. The method of claim 12 or any preceding claim, further comprising, at the preprocessing station, assessing the account.

17. The method of claim 16 or any preceding claim, wherein assessing the account comprises assessing a status of the account.

18. The method of claim 16 or any preceding claim, wherein assessing the account comprises assessing the account for consistency with historical account activity.

19. The method of claim 12 or any preceding claim, further comprising determining a deposit amount to refund an account holder based on scanning those of the plurality of recyclable items associated with the account that are acceptable for recycling.

20. The method of claim 12 or any preceding claim, further comprising determining an amount of remuneration to provide an account holder based on scanning those of the plurality of recyclable items associated with the account that are acceptable for recycling.

21. A system for processing recyclable items, comprising: means for pre-processing a plurality of recyclable items to assess acceptability of the plurality of recyclable items without counting the plurality of recyclable items; and a counter configured to count the plurality of recyclable items after operation of the means for pre-processing.

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