Device, apparatus and method for material processing

Abstract

A material sorting device, recycling apparatus and method therein, the material sorting device comprising: a rotatable plate comprising: a radially internal section having a radially outward negative gradient; and a radially external section having a radially outward positive gradient; thereby creating a trough between the internal section and the external section of the plate; a material removal module comprising at least one component for moving material radially outward across the rotatable plate; a support structure supporting the material removal module and rotatably supporting the rotatable plate; and a control system comprising: a camera configured to scan images of the material on the rotatable plate; an artificial intelligence identification module configured to identify, from the scanned images of the material: individual items; and a characteristic of each item, from a predetermined plurality of characteristics; wherein the control system comprises computer readable media with instructions that, when executed on a processor, performs the task for each identified item of:activating a component of the material removal module, dependent on the identified characteristic, to move the item of the identified characteristic off the rotatable plate at a predetermined rotational position.

Description

[0001] DEVICE, APPARATUS AND METHOD FOR MATERIAL PROCESSING

[0002] Field of the invention

[0003] The present invention relates to a device, apparatus and method for material recycling. In particular, the present invention relates to an apparatus having a compact design for on-site sorting of mixed waste material, and a method of using said apparatus thereof.

[0004] Background

[0005] Processing waste has become a significant environmental challenge globally, with millions of tons of waste material ending up in landfills and oceans each year. Plastic waste is of particular concern due to its prevalence of use, difficulty to reuse, and environmental impact such as by the generation of microplastics which pollute the ecosystem. The need for effective recycling systems, such as plastic recycling systems, is more pertinent than ever. There exist systems that are designed to sort, process, and recycle various types of materials, including plastic material, thereby reducing environmental pollution.

[0006] Some recycling systems rely on manual sorting and basic mechanical processes. These methods are labour-intensive, time-consuming, and prone to errors, leading to inefficiencies and lower recycling rates. In the case of mixed plastic waste, the complexity of plastic, which includes different types of plastics with varying properties, further complicates the recycling process. Yet further, these systems are often large and of industrial scale and are, thus, located off-site. Waste material is, therefore, transported long distances, further contributing to the environmental impact of the waste.

[0007] A particular challenge in plastic recycling is the accurate identification and sorting of different types of plastics. Contaminants, mixed materials, and the presence of additives can hinder the recycling process. Moreover, the lack of advanced technologies to automate and optimize sorting processes results in significant amounts of recyclable plastics being discarded.

[0008] Some recent technologies have introduced more sophisticated methods for recycling. For example, innovations such as infrared spectroscopy have shown promise in improving the accuracy and efficiency of plastic sorting systems. These technologies enable a more precise identification of plastic types and contaminants, facilitating better sorting and higher recycling rates.

[0009] WO2022041867A1 discloses an intelligent sorting device for urban household waste and a method. The device comprises six portions: a basic assembly, a conveyor assembly, a transmission assembly, a power assembly, an image acquisition assembly, and a control assembly. The power assembly comprises a first rotating motor installed between fixing plates and connected to a rotation base, a pneumatic device installed on a first support arm, a second support arm, and a third support arm, a second rotating motor installed at an end of the third support arm, and a motor installed on a robotic arm. The control assembly comprises a solenoid valve installed at a side of the fixing plates, an image processing module and a signal processing unit installed in the interior of the robotic arm, and a signal receiving device and a control module installed on a horizontal conveyor machine. The device acquires an image of a sorting platform by means of a camera, and then controls, by means of the image processing module and the signal processing unit, the robotic arm to grab waste having a large surface area or a sharp shape. In this way, the invention reduces the risks of injury to sorting staff, improving sorting efficiency, and reducing labour costs of sorting operations.

[0010] Despite these advancements, there is still a need for more integrated and efficient recycling systems, in particular for mixed plastics. Current technologies often operate in isolation, lacking the synergy required for optimal performance. An improved system that combines multiple advanced technologies can address the existing gaps and enhance the overall efficiency of plastic recycling. Further, there is a need for effective recycling by a system which is suitable for on-site recycling.

[0011] The present invention aims to provide a comprehensive recycling system that addresses some of the above-described problems. This device and method are designed to accurately identify, sort, and process various types of plastics, including those from complex waste streams such as hospital waste. By automating and optimising the recycling process, the invention seeks to increase recycling rates, reduce environmental impact, and promote sustainable waste management practices.

[0012] Summary of the Invention

[0013] According to a first aspect of the invention there is provided a material sorting device comprising: a rotatable plate comprising: a radially internal section having a radially outward negative gradient; and a radially external section having a radially outward positive gradient; thereby creating a trough between the internal section and the external section of the plate; a material removal module comprising at least one component for moving material radially outward across the rotatable plate; a support structure supporting the material removal module and rotatably supporting the rotatable plate; and a control system comprising: a camera configured to scan images of the material on the rotatable plate; an artificial intelligence identification module configured to identify, from the scanned images of the material: individual items; and a characteristic of each item, from a predetermined plurality of characteristics; wherein the control system comprises computer readable media with instructions that, when executed on a processor, perform the task for each identified item of: activating a component of the material removal module, dependent on the identified characteristic, to move the item of the identified characteristic off the rotatable plate at a predetermined rotational position. The camera may have a predetermined fixed field of view of an area of the rotatable plate.

[0014] To activate a component of the material removal module, dependent on the identified characteristic, the computer readable media of the control system may have further instructions that, when executed on a processor, perform the tasks for each item of: scanning the item when it lies in the camera field of view; assigning the item with an ejection angle with respect to a frame of reference, wherein the frame of reference is a centre of the camera field of view; tracking a rotational position of the rotatable plate with respect to the frame of reference; and activating a corresponding component of the material removal module when the rotational position of the rotatable plate coincides with the ejection angle.

[0015] The radially outward negative gradient of the radially internal section is in the range of 10 to 20 degrees. The gradient may be 15 degrees.

[0016] The radially outward positive gradient of the radially external section is in the range of 35 to 55 degrees. The gradient may be 45 degrees.

[0017] The artificial intelligence identification module may further be configured to estimate a mass of the item using the scanned image of the item; and the computer readable media of the control system may have further instructions that, when executed on a processor, perform the task for each item of adjusting a force from the material removal module based on the estimated mass of the item.

[0018] The support structure may further comprise a collector arrangement, the collector arrangement comprising: at least one collector for collecting material items from the rotatable plate, the at least one collector defined by an area radially outside the rotatable plate and an interior wall of the support structure.

[0019] The material removal module may comprise a fluid jet arrangement disposed in the radial centre of the device, and the at least one component of the fluid jet arrangement may comprise at least one fluid jet. The material removal module may comprise a robotic arm arrangement comprising at least one robotic arm disposed in the radial centre of the device, configured to extend and retract radially across the rotatable plate to urge material items into the at least one collector.

[0020] The collector arrangement may comprise a first collector for material of a first characteristic; and at least one second collector for material of a second characteristic; wherein the first collector and the at least one second collectors each are defined by distinct areas radially outside the rotatable plate and an interior wall of the support structure.

[0021] The at least one fluid jet of the fluid jet arrangement may comprise at least two groups of fluid jets, a first group of fluid jets configured to expel fluid toward the first collector and a second group of fluid jets configured to expel fluid towards the second collector.

[0022] The support structure may further comprise: a sensor arrangement comprising a corresponding sensor for each collector of the at least one collector for detecting a filling level of materials collected within the at least one collector; each of the at least one collector having an evacuation arrangement configured to evacuate material or material items collected within said collector; wherein the computer readable media of the control system have further instructions that, when executed on a processor, perform the tasks of: receiving a signal from the sensor arrangement that a filling level of the at least one collector has reached or exceeded a collector threshold filling level; and evacuating the material or material items collected within a collector by activating a corresponding evacuation arrangement.

[0023] According to a second aspect of the invention, there is provided a material processing apparatus for processing waste material comprising: the sorting device of the first aspect of the invention, the material processing apparatus further comprising: a first shredder disposed within the material processing apparatus in a first position configured to receive material from the collector arrangement; and a first container connected to the first shredder for receiving shredded material from the first shredder.

[0024] The material processing apparatus may further comprise: a second shredder disposed within the material processing apparatus in a second position configured to receive material from the at least one second collector; and at least one second container; wherein the second shredder is connected to a shredded material distribution device arranged to move adjacent an opening of each of the at least one second container to distribute shredded material from the second shredder to the at least one second container.

[0025] The material processing apparatus wherein the support structure may be rotatable to an evacuation position; wherein the computer readable media of the control system may have further instructions that, when executed on a processor, perform the tasks of: rotating the support structure to vertically align the at least one second collector with the second shredder before evacuating the material or material items within a collection area by activating a corresponding evacuation arrangement.

[0026] The material processing apparatus, wherein the at least one second container may comprise at least two second containers; wherein the shredded material distribution device comprises a retaining member for retaining the shredded material; and wherein the computer readable media of the control system further comprise instructions that, when executed on a processor, perform the task of: based on the characteristic of the shredded material, selecting a corresponding second container from the at least two second containers; aligning the shredded material distribution device with the selected second container; and actuating a release of the retaining member upon alignment of the shredded material distribution device with the corresponding container to release the shredded material. The material processing apparatus, wherein the shredded material distribution device may comprise a pump arrangement for creating a negative pressure gradient between the second shredder and the shredded material distribution device.

[0027] The material processing apparatus, wherein the first shredder may be arranged to create a negative pressure gradient along a first shredder output as seen downstream from the first shredder to the first container.

[0028] The material processing apparatus may comprise the support structure, the support structure may comprise the collector arrangement, the collector arrangement may further comprise a waste collector for waste material, the material processing apparatus further comprising: a waste container disposed within the sorting device in a third position configured to receive material from the waste collector.

[0029] The material processing apparatus may further comprise a rail to which the shredded material distribution device is translatably supported, configured to allow a horizontal movement of the shredded material distribution device above each of the at least second containers, in an in-use orientation.

[0030] The material processing apparatus may further comprise: a supply material conveyor for transporting material to the rotatable plate; and wherein the control system is further configured to control an operation of the supply material conveyor dependent on available space on the rotatable plate.

[0031] According to a third aspect of the invention, there is provided a method for sorting material using the material processing apparatus of the second aspect of the invention comprising: feeding material onto the rotating rotatable plate; scanning a predetermined field of view of the rotating rotatable plate with the camera; processing the corresponding scanned image of the field of view with the artificial intelligence identification module to identify: individual items; and a characteristic, from a predetermined plurality of characteristics, of each item identified; and for each item, activating a component of the material removal module, dependent on the identified characteristic, to move the item off the rotating rotatable plate at a predetermined rotational position of the item with respect to a fixed frame of reference.

[0032] The method, wherein the component may be a fluid jet and the material removal module may be a fluid jet arrangement, wherein the activating a component of the material removal module dependent on the identified characteristic to move the item off the rotating rotatable plate at a predetermined rotational position of the item with respect to a fixed frame of reference, comprises expelling fluid, thereby pushing the item off the rotating rotatable plate.

[0033] The method, wherein activating a component of the material removal module dependent on the identified characteristic for each item may comprise: assigning the item with an ejection angle with respect to the fixed frame of reference, wherein the frame of reference is a centre of the camera field of view; tracking a rotational position of the rotatable plate with respect to the frame of reference; and activating the corresponding component of the material removal module when the rotational position of the rotatable plate coincides with the ejection angle.

[0034] The method may further comprise: estimating a mass of the item by further processing of the corresponding scanned image with the artificial intelligence identification module; adjusting a force of the component, based on the estimated mass of the item, to a force to move the item off the rotating plate and into an aligned segregation area.

[0035] The method may further comprise: collecting material of a first identified characteristic into a first collector; collecting material of a second identified characteristic into a second collector; when the first collector has reached or exceeded a first collector threshold filling level, transporting material of the first identified characteristic into a first shredder; when the second collector has reached a second collector threshold filling level, transporting material of the second identified characteristic into a second shredder; further transporting material of the first identified characteristic into a first container; further transporting material of the second identified characteristic into a second container.

[0036] The method, wherein transporting material of the second identified characteristic into a second shredder may comprise rotating the support structure to align the second collector with an opening of the second collector such that material falls under gravity into the second shredder position.

[0037] The method, wherein further transporting material of a second identified characteristic into the second container from the second shredder may comprise: drawing under negative pressure material from the second shredder into a shredded material distribution device; translating the shredded material distribution device into alignment with an opening of a corresponding container; expelling shredded material from the shredded material distribution device upon alignment of the shredded material distribution device with the opening of the corresponding container.

[0038] The device according to the first aspect, the apparatus according to the second aspect, or the method according to the third aspect, wherein the plurality of characteristics comprises a plurality of plastic grades.

[0039] Brief Description of the Drawings

[0040] Fig. 1 a shows a top down, perspective view of an example sorting device of the invention for use in a material processing apparatus;

[0041] Fig. 1 b is a schematic representation of a top-down view of an example sorting device according to the invention;

[0042] Fig. 2 shows a bottom up, perspective view of the example sorting device for use in a material processing apparatus; Fig. 3 shows a central module of the example sorting device with a housing removed;

[0043] Fig. 4 shows an example material processing apparatus of the invention comprising the example sorting device;

[0044] Fig. 5 shows a section of the example material processing apparatus;

[0045] Fig. 6a shows another top-down, perspective view of the example material processing apparatus;

[0046] Fig. 6b shows a front-on view of the example material processing apparatus;

[0047] Fig. 7a shows a perspective view of an exemplary material process apparatus;

[0048] Fig. 7b shows a side view of the exemplary material process apparatus of Fig. 7a;

[0049] Fig. 7a shows another perspective view of the exemplary material process apparatus of Fig. 7a;

[0050] Fig. 8a shows the spatial relationship between the support structure and a first and a second shredder of a material processing apparatus, when the support structure is in a first evacuation position;

[0051] Fig. 8b shows the spatial relationship between the support structure and a first and a second shredder of a material processing apparatus, when the support structure is in a second evacuation position;

[0052] Fig. 9a shows a perspective view of selected components of the material processing apparatus;

[0053] Fig. 9b shows a top-down view of the material processing apparatus of Fig. 9a;

[0054] Fig. 10 shows another perspective view of the material processing apparatus of Fig. 9a;

[0055] Fig. 11a is a flow chart of a method for sorting material according to an example of the invention;

[0056] Fig. 11 b is a flow chart of a method for sorting material according to another example of the invention;

[0057] Fig. 11 c is a flow chart of a method for sorting material according to another example of the invention; and

[0058] Fig. 11d is a flow chart of a method for sorting material according to another example of the invention. Adaptations, variations, modifications, and equivalent arrangements are implicitly disclosed by the examples described herein and fall within the scope of the present disclosure. Accordingly, while examples are described herein in detail in relation to one or more figures, it is to be understood that this disclosure is illustrative and exemplary of the present disclosure.

[0059] The following detailed description refers to the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the following description to refer to the same or similar elements. While many examples of the disclosure may be described, modifications, adaptations, and other implementations are possible, except where clearly incompatible. For example, substitutions, additions, or modifications may be made to the elements illustrated in the drawings, and the methods described herein may be modified by substituting, reordering, or adding stages to the disclosed methods.

[0060] Definitions

[0061] Unless otherwise defined, all terms of art, notations and other scientific terms or terminology used herein are intended to have the meanings commonly understood by those of skill in the art to which this invention pertains. In some cases, terms with commonly understood meanings are defined herein for clarity and / or for ready reference, and the inclusion of such definitions herein should not necessarily be construed to represent a substantial difference over what is generally understood in the art.

[0062] Detailed Description

[0063] Examples of the present disclosure will now be described with reference to the attached figures. It is to be noted that the following description is merely used for enabling the skilled person to understand the present disclosure, without any intention to limit the applicability of the present disclosure to other examples which could be readily understood and / or envisaged by the reader.

[0064] Figure 1 a shows a top down, perspective view of a sorting device 100 for use in a material processing apparatus. The sorting device 100 has a rotatable plate 102, a material removal module 1080, and a support structure 110. The material removal module comprises at least one component for moving material radially outward across the rotatable plate. In some examples, the material removal module comprises a fluid jet arrangement or a fluid suction arrangement. In some examples, the at least one component of the material removal module is at least one nozzle. In some examples the nozzle is a fluid jet. In some examples the nozzle is a fluid suction channel. In the example of Figure 1 a, the material removal module comprises a fluid jet arrangement 108. Further in the example of Figure 1a, the at least one component is at least one fluid jet for expelling fluid radially outward across the rotatable plate.

[0065] The support structure supports the material removal module 1080. In the present example of Figure 1a, it supports the fluid jet arrangement 108. The rotatable plate 102 is rotatably supported by the support structure 110. In the example of Figure 1a, the support structure 110 is a frame having a square-based horizontal crosssection, i.e., square-based in the x-y plane.

[0066] The rotatable plate 102 has a radially internal section 106 and a radially external section 104. The radially internal section 106 has a radially outward negative gradient. The radially external section 104 has a radially outward positive gradient. The radially outward negative gradient of the internal section 106 abutting the outward positive gradient of the external section 104 creates a trough between the internal section 106 and the external section 104 of the rotatable plate 102.

[0067] In the example of Figure 1 a, the fluid jet arrangement is supported in a centre of the rotatable plate 102. The fluid jet arrangement includes at least one fluid jet 116a, a fluid container (see Figure 3), and a control unit (not shown). The control unit controls activation of a component of the material removal module to move an item off the rotatable plate 102. In this example, the component being a fluid jet, the control unit controls the activation of an appropriate fluid jet 116a at an appropriate time in the operation of the sorting device. The at least one fluid jet 116a is configured to expel fluid radially outward across the rotatable plate 102 to push material off the rotatable plate 102. The central fluid jet arrangement 108 has a housing 108H which encloses the majority of the fluid jet arrangement, providing protection for the fluid jet arrangement. The fluid container, and the control unit are housed within the housing 108H. An aperture of the at least one fluid jet 116a is exposed from the housing 108H such that fluid can be expelled across the rotatable plate 102. Preferably, the fluid is air.

[0068] In an example, the material removal module comprises a fluid suction arrangement comprising at least one fluid suction channel. Each fluid suction channel may have a first end and a second end, said first and second end being fluidly connected. The first end of each of the at least one fluid suction channels may be arranged at a radial position from the centre of the device which is larger than the radius of the rotatable plate, and at a fixed azimuthal position. The second end of each fluid suction channel may be fluidly connected to a fluid suction device. Each fluid suction channel may be configured to create a low- pressure gradient from the first end to the second end. In an example, the fluid is air.

[0069] The at least one fluid suction channel may be disposed radially externally to the rotatable plate and is configured to create a negative air pressure gradient across a radial section of the rotatable plate, to draw items off the plate. Preferably the fluid suction arrangement has between two and four fluid suction channels arranged radially equidistant around the rotatable plate.

[0070] In an example, the material removal module further comprises a robotic arm arrangement. The robotic arm arrangement comprises at least one robotic arm disposed in the radial centre of the device, configured to extend and retract radially across the rotatable plate to urge material items into the at least one collector. For example, in addition to the fluid jet arrangement, the sorting device has an additional mechanical arm for pushing particularly heavy items off the plate. The additional mechanical arm may be advantageous when items for which force from the fluid jet is not sufficient to move the item off the plate.

[0071] In an example, the support structure comprises a collector arrangement. With further reference to Figure 1 a, radially outward from the rotatable plate 102 is a collector arrangement 120. In an example, the collector arrangement comprises at least one collector for collecting material items from the rotatable plate. The at least one collector is defined by an area radially outside the rotatable plate and an interior wall of the support structure.

[0072] Each collector of the at least one collector may have a capacity of 10 kilos. Preferably, the capacity is 5 kilos. More preferably, the capacity is 3 kilos. Even more preferably, the capacity is 7 kilos.

[0073] In an example, the collector arrangement comprises a first collector for material of a first characteristic. The collector arrangement comprises at least one second collector for material of a second characteristic. The first collector and the at least one second collectors each are defined by distinct areas radially outside the rotatable plate and an interior wall of the support structure. With reference to the example of Figure 1 b, where the collector arrangement comprises a first collector 120a and a second collector 120b, the first collector 120a is defined by a first area radially outside the rotatable plate and an interior wall of the support structure, and the second collector 120b is defined by a second area radially outside the rotatable plate and an interior wall of the support structure. In an example, the collector arrangement further comprises a waste collector for waste material.

[0074] In the example of Figure 1 a, a first collector 120a and a second collector 120b are positioned between the rotatable plate 102 and the frame 1 10. Items fed onto the rotatable plate 102, in use, can be sent to either one of the first collector 120a or the second collector 120b, based on their identified characteristics. Each at least one component may be positioned in such a way that an item may be moved off the rotatable plate towards the first collector or the at least one second collectors. In the example where the component is at least one fluid jet, the at least one fluid jet is, therefore, aligned with the first collector or at least one second collector to send the item into said area. Preferably, the sorting device has a collector arrangement having between two and four collectors: a first collector for material of a first characteristic, and at least one second collector for material of a second characteristic or further characteristic. Alternatively, a first collector for items of a first characteristic, and between one and three collectors for items, of a different characteristic. Each characteristic may be the same or different. A further waste collector may be comprised in the collector arrangement. In one example, the first and at least one second collectors are for recyclable items, and the waste collector for non-recyclable items.

[0075] In an example, the support structure comprises a sensor arrangement comprising a corresponding sensor for each collector of the at least one collector for detecting a filling level of materials collected within the at least one collector. Each of the at least one collector has an evacuation arrangement configured to evacuate material or material items collected within said collector. For example, in the example wherein there are two collectors, the sensor arrangement has a first sensor for detecting a filling level of materials collected within the first collector, and a second sensor for detecting a filling level of materials collected within the second collector. In an example, the filling level is reached when a threshold weight is reached for a particular collector. In another example, the filling level is reached when accumulated material in a particular collector reaches a predetermined collector height. The sensor(s) in the sensor arrangement may be optical sensors, laser sensors, weight sensor, to name a few non-limiting examples.

[0076] The trough created between the internal section 106 and the external section 104 of the plate 102 encourages items being fed onto the plate 102 to roll or slide to the lowest point in the trough. In a particular implementation of the sorting device, the waste material to be processed by the sorting device 100 are plastic containers and, in particular, cylindrical plastic containers. Thus, the trough will encourage most of the waste material items to orient lengthways in the trough. This facilitates a stability of the items as they rotate on the plate 102. It also facilitates distribution of the waste material on the plate 102 so that it is more easily imaged by a camera, as will be explained in more detail below. Yet further, having a common orientation of the items of the waste material reduces identification complexity by the control system since it reduces the degree of freedom of the items, as will also be explained in more detail below. Figure 1a shows an example item I, said item being cylindrical in shape, with a length of the item I lying along the trough.

[0077] The sorting device 100 further has a control system (not shown). The control system includes a camera having a view of the rotatable plate 102 and is configured to scan a predetermined, fixed section (field of view) of the rotatable plate at repeated time intervals. In this way, items present on the rotatable plate 102 are imaged. The control system is enabled with an artificial intelligence identification module. An image of the field of view containing items on the rotatable plate 102 is processed by the artificial intelligence identification module to identify items and their particular characteristic from a predetermined plurality of characteristics. Preferably, the particular characteristic is a particular material grade from a plurality of material grades, for example, a particular grade of plastic from a predetermined selection of plastic grades. The selection of plastic grades may include two or more of Polyethylene terephthalate (PET or PETE), High- density polyethylene (HDPE), Polyvinyl chloride (PVC), Low-density polyethylene (LDPE), Polypropylene (PP), and Polystyrene (PS) to name a few non-limiting examples. In another example of the invention, the sorting device is a metal recycling device, and the plurality of characteristics is a predetermined selection of metal elemental composition and / or metal grades. For example, the predetermined selection of metal elemental composition may include some of the following non-limiting list: aluminum, steel, copper, zinc, brass, titanium, lead, and nickel. Of the prior non-limiting list of metal element compositions, the sorting device may further sort the metal material into different metal grades such as different steel grades: 304 stainless steel, 316 stainless steel, and different aluminium grades: 6061 aluminium, 7075 aluminium. In a further example of the invention, the sorting device is a glass recycling device, and the plurality of characteristics is a predetermined selection of types and / or colours of glass. For example, the predetermined selection of types of glass may include some of the following non-limiting list: soda-lime glass, borosilicate glass, lead glass, tempered glass, laminated glass, coloured glass, aluminosilicate glass, fused quartz glass, and fiberglass. Of the coloured glass types, the predetermined plurality of characteristics may include: blue glass, green glass, red glass, amber glass, purple glass, pink glass, yellow glass, black glass, white (opal) glass, turquoise glass, brown glass, grey glass. In a yet further example of the invention, the sorting device is a paper recycling device, and the plurality of characteristics is a predetermined selection of types of paper. For example, the predetermined selection of paper types may include some of the following non-limiting list: cardboard, corrugated cardboard, paperboard, newspaper, high-grade paper, paperboard, contaminated paper, glossy paper, photographic paper, and thermal paper.

[0078] In a particular example of the invention, the camera is an infrared camera which captures images of the camera field of view of the rotatable plate based on infrared radiation having a wavelength in the range of 700 to 900 nanometres. Spectra in the near infrared region in respect of each item detected in the field of view captured image can be compared by the Al module with spectra of known material types and the type identified therein. In another example, the camera is a visible light camera.

[0079] The control system further controls activation of a component of the material removal module, dependent on an identified characteristic, when an item having particular characteristics i.e. a particular plastic grade, is radially aligned with a corresponding collector. In the example shown in Figures 1 a, 1 b, the control system controls the activation of a correct fluid jet of the fluid jet arrangement. For example, the control system sends a signal to the control unit of the fluid jet arrangement to activate the correct predetermined fluid jet(s) of the fluid jet arrangement to push the item off the rotatable plate 102 at the correct predetermined rotational position. Alternatively, the control system sends a signal to the control unit of the fluid suction arrangement to activate the correct predetermined fluid suction channel(s) of the fluid suction arrangement to move the item off the rotatable plate 102 at the correct predetermined rotational position.

[0080] More specifically, the control system is configured to scan a predetermined fixed field of view of an area of the rotatable plate. Scanning the field of view of the rotatable plate comprises rapid capture of images of the field of view at predetermined time intervals. Items that were lying in the camera field of view at the particular time interval will thus be captured in the corresponding image. Al processing of the images identifies individual items in the image and a particular characteristic of each identified item from the predetermined plurality of characteristics. A particular ejection angle is assigned to each identified item with respect to a frame of reference. Preferably, the frame of reference is a centre of the camera field of view. The ejection angle is dependent on the particular characteristic and corresponds to a rotational position of a corresponding segregation area for collection of the particular material characteristic. The control system is further configured to track a rotational position of the rotatable plate with respect to the frame of reference and activate a corresponding portion of the fluid jet arrangement when the rotational position of the rotatable plate coincides with the ejection angle of a selected item.

[0081] Figure 1 b is a schematic representation of a top-down view of an example sorting device according to the invention. As shown by the axes, the schematic representation is in the x, y plane. Figure 1 b illustrates how the control system of the sorting device is configured to activate a component, in this example a fluid jet, of the material removal module, in this example the fluid jet arrangement, dependent on the identified characteristic, to move the item of the identified characteristic off the rotatable plate at a predetermined rotational position. Figure 1 b shows a top-down view of the rotatable plate 102 including the internal section 104, the external section 106, the supporting structure 110, first and second collectors, the concentrically arranged fluid jet arrangement 108, a first fluid jet 116a of the fluid jet arrangement 108, and a second fluid jet 116b of the fluid jet arrangement 108. Further shown in Figure 1 b is a field of view 105 of the camera, an initial (reference) rotational position Ro, a first rotational position Ri, and a second rotational position R2. The first rotational position R1 radially aligns with the first collector and a second rotational position R2 radially aligns with the second collector. From the rotational centre of the rotatable plate, the first rotational position R1 is at an angle a from the reference rotational position Ro. From the rotational centre of the rotatable plate, the second rotational position R2 is at an angle [3 from the reference rotational position Ro. The camera is configured to continuously monitor the field of view 105 of the rotational plate 102. When it detects that one or more items enter the field of view, the resulting image is analysed by the Al module which detects the number of items in the image and a predetermined characteristic of each detected item, for example its grade of plastic. Based on the detected characteristic, the item is assigned an ejection angle corresponding to a rotational position aligning with a segregation area elected to segregate material of that particular characteristic. Each item is assigned an identification number and its Cartesian coordinates in the x-y plane with respect to a reference point, for example the rotational centre of the rotatable plate, are calculated. For each item, the identification number, Cartesian coordinates and ejection angle are stored in memory in the control system, for example in cache memory. The control system continuously monitors the angle of the rotatable plate and the assigned angle of the item(s) present on the rotatable plate. The relative angle of the items(s) determines if the corresponding part of the fluid jet arrangement is activated to propel the item off the rotatable plate. In the example of Figure 1 b, the fluid jets 1 16a are activated when the rotational plate has rotated by the angle a with respect to the reference rotational position Ro after items having the ejection angle a are detected in the field of view. The fluid jets 116b are activated when the rotational plate has rotated by the angle [3 with respect to the reference rotational position Ro after items having the ejection angle [3 are detected in the field of view. In the example of Figure 1 b, two items h, I2 are shown in the camera’s field of view. In a hypothetical example, item I1 is made from PET and item I2 is made from PVC. Item h is outside the camera’s field of view and so is not captured in the image taken during the particular time interval. In the hypothetical example, items detected by the Al module made from PET are assigned an ejection angle a and items detected by the Al module made from PVC are assigned an ejection angle [3. Thus, item h is assigned the ejection angle a and item I2 is assigned the ejection [3. As further shown in Figure 1b, new material 103 comprising a collection of items for processing is supplied to the rotatable plate 102. As these items eventually enter the camera’s field of view, they are likewise assigned an ejection angle. In this way, all PET material is segregated into the first collector and all PVC material is segregated into the second collector. In an alternative illustrative hypothetical, non-recyclable plastic items are assigned an ejection angle a, and all recyclable plastic items are assigned an ejection angle [3. Non-recyclable material is segregated into the first collector for landfill disposal or incineration, and recyclable material is segregated into the second collector, with particular grades of recyclable plastic sorted out sequentially.

[0082] As shown in Figure 1 b, the incoming material 103 to be released onto the rotatable plate 102 is that the control system has not detected an object in the relevant area on the rotatable plate in which the material is to be released onto. Given a counterclockwise movement of the rotatable plate 102, the inbound material is released onto the rotatable plate after the camera field of view relative to the rotational direction. This allows time for the items in the material to stabilise on the rotatable plate before they move into the camera field of view.

[0083] In an example of the invention, the sorting device further comprises means for estimating a mass of a particular item on the rotatable plate 102. The means for estimating the mass can comprise the Al identification module of the control system. In the example sorting device 100 of Figures 1a and 1 b, the estimated mass can be signaled to the material removal module 1080 which is configured to adjust a force directed at the particular item. In the examples where the material removal module 1080 is a fluid jet arrangement or a fluid suction arrangement, the force may be adjusted by adjusting a flow rate of fluid expulsion directed at the particular item. In this way, an appropriate force is provided per item to move, i.e. suck or push the item out of the trough and into the collector arrangement. In a similar manner wherein the sorting device uses a fluid suction arrangement, a flow rate of the fluid suction channel is adjusted. Figure 2 shows a bottom up, perspective view of the sorting device 100 for use in a material processing apparatus. Figure 2 shows an underside of the rotatable plate 102, an underside of the frame 110, a motor 112 coupled between the frame 110 and the rotatable plate 102, and roller wheels 114. Roller wheels 114 rotatably support the rotatable plate 102 whilst allowing rotational motion.

[0084] Figure 3 shows the central fluid jet arrangement 108 of the sorting device 100 with a frustoconical housing removed. Housed within the housing is a fluid container 120, a set of valves 118 and the control unit to control the fluid jet arrangement. A portion of the jets are also housed within the housing. Another portion of the jets are embedded within the housing with exposed apertures. The fluid container 120 is fluidly coupled to the set of valves, which are fluidly coupled to the fluid jets. In this way, upon a signal from the control system, the control unit configures the valves such that a fluid pathway is established to the appropriate (predetermined / desired) fluid jet nozzles. The control unit then releases fluid from the fluid container 120. Fluid is, thus, expelled across the correct predetermined section of the rotatable plate 102 towards a predetermined item, to move the item into the corresponding segregation area. The housing 108H (see Figure 1 ) protects the fluid container 120, a set of valves 118, the control unit, and the portion of the jet housed within the housing. In particular the housing 108H (see Figure 1 ) protects these elements from incoming waste material.

[0085] Preferably, the fluid jet arrangement has at least one set of fluid jets for ejection of fluid to move supply material off the rotatable plate 102. More preferably, the fluid jet arrangement has at least two sets of fluid jets, one for segregation of non- recyclable material and one for segregation of recyclable material. In the particular example of Figure 3, the fluid jet arrangement includes four sets of fluid jets, three of the sets of jets are shown in the figure, 116a, 116b, 116c. The fourth set of fluid jets is out of view.

[0086] Figures 4-7a show exemplary material processing apparatuses. Each exemplary material processing apparatus comprises the sorting device 100, a first shredder disposed within the material processing apparatus in a first position configured to receive material from the collector arrangement, and a first container connected to the first shredder for receiving shredded material from the first shredder.

[0087] Figure 4 shows a material processing apparatus 200 incorporating the sorting device 100. The material processing apparatus 200 has a supply material conveyor 208, sorted material containers 204, 206, a recycled material conveyor 210, a shredder 212, and a scaffold 213. The sorted material containers 204, 206 receive sorted material from the sorting device 100. The supply material conveyor 208 transports material to the sorting device 100. Preferably, the supply material conveyor, which delivers material comprised of mixed items, is controlled by the control system of the sorting device. The supply material conveyor is activated and when the control system confirms that a location of material delivery is unoccupied by any material already on the rotatable plate. The location of material delivery is rotationally in front of the camera’s field of view.

[0088] Figure 4 shows a first collector 202a and a second collector 202b attached to the frame 110 of the sorting device 100. The first collector 202a collects non- recyclable material, for subsequent transportation into material container 204 which is a container for non-recyclable waste material. The material container 204 lies vertically beneath the collector 202a. The waste material can be removed and transported to landfill or for incineration. The second collector 202b collects recyclable material sorted by the sorting device 100 to the shredder 212 lying vertically below.

[0089] Sorted material containers 206 include a plurality of containers 206-A, 206-B, 206- C, 206-D. Each container 206-A, 206-B, 206-C, 206-D is for receiving sorted material of a particular characteristic, i.e., the characteristic identified by the control system. In an example, each container is for receiving a particular grade of plastic. In the example of Figure 4, the sorted material containers include four containers 206-A, 206-B, 206-C, 206-D, each container for receiving a particular grade of material, e.g. plastic. In the example of Figure 4, the recycled material conveyor 210 transports shredded material from the shredder to the correct container 206 based on the identified characteristic of the shredded material. In some example apparatuses of the invention, the shredder, as thus the shredding step, is omitted. In these setups, sorted recyclable material items are transported intact to the corresponding container.

[0090] In some examples, in order to have shredded material of a uniform characteristic at any one time, the control system tracks all the items having a particular characteristic and identifies these as targets to be moved into the second collector 202b by the fluid jet arrangement. In this way all the material being fed into the shredder in a particular time duration in the sorting process is of a uniform characteristic. The uniform characteristic shredded material is then delivered to the appropriate container. This is explained in more detail with reference to the flowchart in Figure 11 a.

[0091] Figure 5 shows a section of the material processing apparatus 200. In particular, an expanded view of the supply material conveyor 208, the recycled material conveyor 210 and the container 206-C are shown. Chutes create a passageway from the conveyor 208 to the respective container 206. Preferably, each container 206 has a corresponding chute 214. In Figure 5, chute 214-D and chute 214-C are shown and are configured to direct recycled shredded material into the containers 206-D and 206-C, respectively. Figure 5 further shows that the containers 206 are mounted on a slider 216. The slider 216 allows the containers to be slid forward from the rest of the apparatus 200 for easy removal of the containers 206.

[0092] Figure 6a shows the material processing apparatus 200 with the slider 216 extended. The containers 206 are easily accessible, removable and / or replaceable from the apparatus such that the sorted, and optionally shredded, material can be collected for onward processing. A supervisor S is shown who can easily remove the containers from the apparatus 200 and from the shelter 302. Figure 6b shows the material processing apparatus housed within a shelter 302. The slider 216 allows the containers 206 to be extended out from and retracted into the rest of the apparatus 200 and the shelter 302. In Figure 6b, the slider 216 is in the retracted position. In Figure 6b, the slider 216 is retracted. Containers may be aligned with their respective chutes 214 on the conveyor 210. The shelter 302 has doors 306 which can be closed to protect the apparatus 200 from the elements or from tampering. Also shown in Figures 6a and 6b is a supply material bin 304. Mixed waste material can be unloaded into the supply material bin 304. Material is taken by the conveyor 208 from the supply material bin 304 at a steady rate and delivered to the sorting device 100.

[0093] The material processing apparatus of Figures 7a-7c comprises a supply material conveyor 808 for transporting material to the rotatable plate.

[0094] In an example, the material processing apparatus further comprises a second shredder disposed within the material processing apparatus in a second position configured to receive material from the at least one second collector. The material processing apparatus further comprises at least one second container. The second shredder is connected to a shredded material distribution device arranged to move adjacent an opening of each of the at least one second container to distribute shredded material from the second shredder to the at least one second container.

[0095] In an example, wherein the at least one second container comprises at least two second containers, the shredded material distribution device comprises a retaining member for retaining the shredded material.

[0096] In an example, the support structure 110 of the material processing apparatus is rotatable to an evacuation position. Figure 8a and Figure 8b show the rotatable support structure of a material processing apparatus, at two different evacuation positions. The remaining components of the material processing apparatus are omitted for better illustration. The material processing apparatus in Figures 8a, 8b comprise a first shredder 801 disposed within the material processing apparatus in a first position configured to receive material from the collector 120a. The material processing apparatus in Figures 8a, 8b comprises a second shredder disposed within the material processing apparatus in a second position configured to receive material from the second collector 120b. In Figure 8a, the first shredder 801 and the first collector 120a, are not aligned. The same applies to the second shredder 802 and the second collector 120b. In Figure 8b the support structure is rotated into an evacuation position. In this example this rotation is by 90 degrees. In Figure 8b the first shredder 801 is aligned with the first collector 120a and the second shredder 802 is aligned with the second collector.

[0097] Figures 9a and 9b show a material processing apparatus with selected components. The support structure, the rotatable table, and the supply material conveyor, for example, have been omitted from the Figures to allow for better illustration of the remaining components. The material processing apparatus further comprises a first container 810. The material processing apparatus further comprises at least one second container 820. In this example, it comprises two second containers 820a, 820b. Further second containers may be adapted to the material processing apparatus. In the example of Figure 9a, a further container 830 may be positioned adjacent to the second container 820b and aligned with the rest of the containers. The further container may be configured to be disposed within the material processing apparatus in a position configured to receive material from the waste collector. Alternatively, the further container 830 may be a further second container 820c. In that case, the rail of the shredded material distribution device (as further explained below) will have to be expanded to be arranged to move adjacent an opening of the further second container 820c. Preferably, the further container 830 is configured to receive shredded material from the first shredder, in the similar manner to the first container 810.

[0098] In an example, the computer readable media of the control system have further instructions that, when executed on a processor, perform the tasks of receiving a signal from the sensor arrangement that a filling level of the at least one collector 120 has reached or exceeded a collector threshold filling level, and evacuating the material or material items collected within a collector 120 by activating a corresponding evacuation arrangement. In another example, the computer readable media of the control system have further instructions that, when executed on a processor, perform the tasks of rotating the support structure so that the at least one collector vertically aligns with the at least one second shredder 802 before evacuating the material or the material items within a collector by activating a corresponding evacuation arrangement. In another example, the computer readable media further have instructions that, when executed on a processor, perform the task for each identified item of based on the characteristic of the evacuated material or material items, selecting a corresponding second container from the at least two second containers, and aligning the shredded material distribution device with the corresponding second container to lead shredded material from the shredded material distribution device to the corresponding second container. The computer readable media of the control system have further instructions that, when executed on a processor, perform the tasks of, based on the characteristic of the shredded material, selecting a corresponding second container from the at least two second containers, aligning the shredded material distribution device with the selected second container, and actuating a release of the retaining member upon alignment of the shredded material distribution device with the corresponding container to release the shredded material.

[0099] With further reference to Figures 9a, 9b, the first shredder 801 is connected to the first container 810. The second shredder 802 is connected to a shredded material distribution device 850 configured to distribute shredded material from the second shredder 802 to the at least one second container 820.

[0100] Figure 10 shows a perspective view of Figures 9a and 9b for illustrating the shredded material distribution device. The shredded material distribution device comprises a pump arrangement 852 for creating a negative pressure gradient between the second shredder 802 and the shredded material distribution device 850. The first shredder output 801 a is arranged adjacent an opening 811 of the first container 810. In an example, the first shredder is arranged to create a negative pressure gradient along a first shredder output as seen downstream from the first shredder to the first container. In the example of Figures 9a-9b, the first shredder 801 is arranged to create a negative pressure gradient along a first shredder output 801 a.

[0101] With further reference to Figures 9a, 9b, and 10, the shredded material distribution device 850 is arranged to move adjacent an opening 821 a, 821 b of each of the at least one second container 820a, 820b.

[0102] In an example, the material processing apparatus further comprises a rail to which the shredded material distribution device 850 is translatably supported, configured to allow a horizontal movement of the shredded material distribution device 850 above each of the at least second containers, in an in-use orientation. An exemplary rail 851 a, 851 b is illustrated in the exemplary apparatus of Figures 9a, 9b, 10.

[0103] With reference to Figures 7a, 7c, the material processing apparatus has an external frame 860. The external frame 860 supports the rail 851 a, 851 b to which the shredded material distribution device 850 is translatably supported. Further supported by the external frame 860 is at least one container retainer hatch 861 a- 861 d. Each container retainer hatch 861 a-861 d is configured to secure a corresponding container 810, 820a, 820b, 830 when the container retainer hatch 861 a-861 d is in a first closed position. For example, in Figure 7c, container hatches 861 a-861 c are illustrated in the first closed position. Each container retainer hatch 861 a-861 d is further configured to allow the release of the container 810, 820a, 820b, 830 from the material processing apparatus. Each container retainer hatch 861 a-861 d is translatable between the first closed position and a second open position. Each container retainer hatch 861 a-861 d is hinged at a bottom edge to a bottom edge 871 of the external frame 860, in the in-use orientation. Each container retainer hatch 861 a-861d is translated from the first closed position to the second open position by rotating the hatch about its hinged and resting the opened hatch on a ground surface outside the material processing apparatus. When the container retainer hatch 861a-861d is in the second open position, the corresponding container 810, 820a, 820b, 830 may slide on a surface (or track) of the container retainer hatch 861 a-861d in order to be removed from the material processing apparatus. For example in Figure 7c, the container retainer hatch 861 d is shown in the second open position. The container 830 can be removed from the material processing apparatus. In the example of Figures 7a- 7c, each container 810, 820a, 820b, 830 is equipped with wheels which, upon engagement with the track created by the container retaining hatch 861 a-861d, can allow the easier extraction of the container 810, 820a, 820b, 830 from the material processing apparatus.

[0104] In an example, the material processing apparatus comprises two shredders. The first shredder is configured to shred material of a first characteristic, for example PET which is relatively sensitive compared to other types of plastic. Material of a second characteristic, such as other types of plastic are shredded in the second shredder. This may a useful when high quality of a material of a specific characteristic, PET in this example, is required. Shredding material through the shredder may leave residues which may be transferred into the following batch. By separating the shredding process to exclusively the first shredder for one characteristic, for example PET, high quality material may be obtained.

[0105] The second shredder of that example may be configured to shred materials of a second characteristic, or that are relatively larger than the material processed in the first shredder, for example plastic material up to 10 litres. This second shredder may shred material into 8 to 10 millimetres flakes. These flakes may be distributed by the material distribution device 850 into the correct container based on the identified characteristic. Each container may contain a bag. Each bag may collect material weighing between 150-300 kilos, such as 200 kilos, or 250 kilos. For the container collecting material PET, a bag may collect material weighing 200-250 kilos, such as 225 kilos.

[0106] The material processing apparatus of the invention is organised into two levels with the sorting device and shredded material distribution device on a first (top) level, and the at least one shedder and at least one container on a second (bottom) level. The sorting device and shredded material distribution device are arranged above the at least one shedder and at least one container. In the example of Figure 7a to 7c, four containers and a waste container, and a first and a second shedder are organised on the second (bottom) level, and the sorting device and shredded material distribution device are organised on the first (top) level. The material conveyor extends at an acute angle from the second (bottom) level to the first (top) level. In this way, elements of the material processing apparatus according to the invention can be arranged in a smaller footprint than otherwise achievable. In this way, the material processing apparatus according to the invention provides better utilisation of space. A compact design is therefore offered. This is particularly beneficial when the material processing apparatus is to be used in urban areas or commercial areas. In a particular example, the material processing apparatus of the invention is for use in processing hospital waste and is therefore to be stationed in the grounds of a hospital where real estate is limited. A compact design is, therefore, particularly beneficial for this use case.

[0107] Figure 11 a is a flow chart of a method 900a for sorting material. At 910, mixed material is fed onto a rotatable plate.

[0108] Preferably, the mixed waste material is at least partially made up of plastic items. More preferably, the plastic items are of plastic from a plurality of plastic grades. In a particular example, mixed waste material is mixed waste plastic packaging. In a specific example, the mixed waste material is plastic waste packaging from hospitals. Plastic waste from hospitals is a particularly significant due to the extensive use of single-use items like medical devices, packaging materials, personal protective equipment, and disposable items.

[0109] At 920, the material is scanned with a camera of a control system. The camera has the capability of scanning the items whilst the items are in rotational motion on the rotatable plate. An infrared camera may be used which captures images based on infrared radiation having a wavelength in the range of 700 to 900 nanometres. In order to scan items of the material, the camera continuously monitors a field of view of the rotation plate. Images of the field of view are stored and analysed when it is detected that at least one item is present in the field of view.

[0110] At 930, for each item of the mixed waste material, at least one characteristic of the item is identified by the control system, the control system enabled with an artificial intelligence (Al) identification module. The Al module leverages machine learning to detect separate items in an image of the field of view containing one or more items and analyse each item to classify its type (characteristic). The Al module processes the captured images of the items through the trained Al model. In the example wherein the at least one characteristic of the items is different grades of plastic, training data for establishing the trained Al model can include labelled examples of various plastic grades, encompassing spectral data, images, and physical properties. The machine learning process involves data preprocessing, feature extraction, model selection, training, validation, and testing. The integrated trained model captures real-time images, for example IR images of the items, makes predictions, and sorts the plastics by identified grade, accordingly. In the more specific example of plastic hospital waste, the Al module can be specifically trained on common single-use hospital plastic items and packaging.

[0111] At 940, the control system further identifies when an item having the particular identified characteristic is radially aligned with a respective predetermined collector radially out from the rotatable plate, said collector in radial alignment with the corresponding component of the material removal module, for example corresponding fluid jets of the fluid jet arrangement. This is achieved by assigning each item with an ejection angle with respect to the fixed frame of reference, wherein the frame of reference is a centre of the camera field of view, tracking a rotational position of the rotatable plate with respect to the frame of reference, and activating the corresponding component, for example the fluid jet, of the material removal module, for example the fluid jet arrangement, when the rotational position of the rotatable plate coincides with the ejection angle.

[0112] At 950, the correct component of the material removal module is activated upon identification that an item having a particular identified characteristic is radially aligned. The item is therefore pushed into the correct collector i.e., predetermined collector, 960.

[0113] In an example, the component is a fluid jet and the material removal module is a fluid jet arrangement. The activating 950 a component of the material removal module dependent on the identified characteristic to move the item off the rotating rotatable plate at a predetermined rotational position of the item with respect to a fixed frame of reference, comprises expelling fluid, thereby pushing the item off the rotating rotatable plate.

[0114] When the method involves using a sorting device with two collectors for separating out the material on the rotatable plate, wherein one area is for non-recyclable waste and another area is for recyclable waste, items of the same characteristic must be separated from the rotatable plate into the recyclable material collector in sequence. Once all of the material of a particular characteristic is pushed off the rotatable plate and into the recyclable material collector, the collected material of the same characteristic can be released together into a shredder, 970. Since said recyclable waste will be sent from the segregation are to the shredder together (in batch), all of the recyclable waste sorted into the collector should be of the same characteristic, i.e., a homogeneous grade of plastic. Wherein there are only two collectors: one for non-recyclable landfill waste and one for recyclable material, all the items of a first characteristic on the rotatable plate are sorted out first, i.e., steps 940, 950 and 960 are repeated until all the items of the first characteristic are in the collector, 965. After evacuation of the collected recyclable material of a first characteristic, the method can progress to identifying and sorting out items of a second characteristic, 985. Again, once all the items of the second characteristic are in the collector, the items of the second characteristic are released into a shredder for shredding, 970. Post-shredding, the shredded recyclable material is transported to a container for collection of shredded recyclable material of the second characteristic, different from the container for collection of shredded recyclable material of the first characteristic, 980. Concurrently to the sorting of recyclable material from the rotatable plate, non- recyclable material can be sorted. After scanning mixed waste material with the camera 920, non-recyclable material is identified 935. It is then identified when the non-recyclable item is radially aligned with the collector for non-recyclable waste, 945, and thus also aligned with corresponding component of the material removal module, for example correct fluid jet(s) of the fluid jet arrangement. At 955, the correct component(s) of the material removal module is activated. The non- recyclable item is then moved into the collector for non-recyclable waste, 975, then the item drops into a non-recyclable waste container, 985.

[0115] The process may end when all of the items in the mixed waste material on the rotatable plate and fed from the supply conveyor have been processed, at 995.

[0116] In a particular example, method 900a is implemented on the sorting device 100 and apparatus 200 of the present invention, when apparatus 200 has two collectors: one collector 202b for collection of recyclable material, and one collector for collection of non-recyclable material 202a. Mixed waste material is fed 910 onto the rotatable plate 102 by the conveyor 208. Preferably, mixed waste is deposited in bulk into a supply material bin, such as supply material bin 304, and is taken up by the conveyor 208 at a constant and steady rate, or a rate determined by the control system informed by available space in the delivery zone of the rotatable plate. The camera of the control system of the sorting device 100 scans mixed waste 920 in the field of view of the camera, identifies items and their characteristics in the scanned mixed waste 920, identifies when items of a first characteristic are radially aligned 940, and sends a signal to the control unit of the fluid jet arrangement 108 to activate 950 the correct fluid jet(s) 116a of the fluid jet arrangement 108. In an example, the control unit of the fluid jet arrangement 108 activates 950 the correct fluid jet(s) 116a of the fluid jet arrangement 108. Fluid expelled from the fluid jet(s) 116a propels the item into the correct collector 202b. The shredder 212 shreds the material of homogeneous characteristic released 970 from the collector 202b. The conveyor 210 transports 980 the shredded material into the first container 206-A for collection of recycled material of the first characteristic. The process is then repeated for items identified with a second characteristic and a third characteristic and a fourth characteristic, with the conveyor 210 transporting shredded material of the second and third and fourth characteristic into the second container 206-B, third container 206-C and fourth container 206-D, respectively.

[0117] Figure 1 1 b is a flow chart of a method 900b for sorting waste material according to another example of the invention.

[0118] At 910, mixed waste material is fed onto a rotatable plate. When the method involves using a sorting device with more than two collectors for separating out the material on the rotatable plate, wherein one area is for non-recyclable waste and two or more areas are for recyclable waste, item separation based on a predetermined characteristic can be separated from the rotating concurrently for the two or more characteristics. Whilst the method of Figure 1 1 b demonstrates concurrent separation of three different grades of plastic and non-recyclable waste, other arrangements are possible. For example, two grades of plastic, more than three grades of plastic, or an alternative characteristic to plastic grade are all within the scope of the invention.

[0119] The method 900b of Figure 11 b starts in the same way as the method 900a in Figure 1 1 a, wherein mixed waste material is fed onto the rotatable plate, 910, and then scanned with a camera of a control system, 920. Since the method 900b is implemented by a sorting device having a separated collector for each identified characteristic (plastic grade), separation of the items having different characteristics can be sorted concurrently.

[0120] The method 900b is demonstrated with the particular characteristics being different grades of plastic, however, it can equally be other characteristics of a material desirable for separation, such as metal types and grades, paper types and grades, and glass type and colour, as described above.

[0121] In the illustrative example of mixed plastics and a fluid jet arrangement, at 930a items are identified by the control system that are of a first grade of plastic, such as PET. At 940a, the control system determines when this item is aligned with a first collector for receiving sorted first grade plastic. At 950a, a first fluid jet or set of fluid jets in the fluid jet arrangement, that is radially aligned with the first collector and thus the item of first grade, is activated to expel fluid at the item and propel the item off the rotatable plate and into the first collector. At 965a, the control system identifies whether all of the items of a first grade of plastic are sorted from the rotatable plate into the first collector. If the control system deems, at 965a, that all of the items of first grade plastic are sorted, the first-grade items can be funnelled in batch into a shredder, 970a, and then transported into a first container, 980a. If the control system deems, at 965a, that not all of the items of first grade plastic are sorted, the method returns to step 930a, wherein further items of first grade plastic are identified.

[0122] Concurrently with steps 930a to 980a, steps 930b to 980b can occur. At 930b items are identified by the control system that are of a second grade of plastic, such as HDPE. At 940b, the control system determines when this item is aligned with a second collector for receiving sorted second grade plastic. At 950b, a second fluid jet or set of fluid jet in the fluid jet arrangement, that are radially aligned with the second collector and thus the item of second grade, is activated to expel fluid at the item and propel the item off the rotatable plate and into the second collector. At 965b, the control system identifies whether all of the items of a second grade of plastic are sorted from the rotatable plate into the second collector. If the control system deems, at 965b, that all of the items of second grade plastic are sorted, the second-grade items can be funnelled in batch into a shredder, 970b, and then transported into a second container, 980b. If the control system deems, at 965b, that not all of the items of second grade plastic are sorted, the method returns to step 930b, wherein further items of second grade plastic are identified.

[0123] Concurrently with steps 930a to 980a, and steps 930b to 980b, steps 930c to 980c occur. At 930c items are identified by the control system that are of a third grade of plastic, such as PVC. At 940c, the control system determines when these items are aligned with a third collector for receiving sorted third grade plastic. At 950c, a third fluid jet or set of fluid jet in the fluid jet arrangement, that are radially aligned with the third collector and thus the item of third grade, is activated to expel fluid at the item and propel the item off the rotatable plate and into the third collector. At 965c, the control system identifies whether all of the items of a third grade of plastic are sorted from the rotatable plate into the third collector. If the control system deems, at 965c, that all of the items of third grade plastic are sorted, the third-grade items can be funnelled in batch into a shredder, 970c, and then transported into a third container, 980c. If the control system deems, at 965c, that not all of the items of third grade plastic are sorted, the method returns to step 930c, wherein further items of third-grade plastic are identified.

[0124] Concurrently with steps 930a to 980c, steps 935 to 985 also occur. Steps 935 to 985 are comparable to steps 935 to 985 for method 900a. Non-recyclable material is identified, 935. It is then determined when the non-recyclable item is radially aligned with the fourth collector for non-recyclable waste, 945, and thus also aligned with the corresponding correct part of the fluid jet arrangement (corresponding predetermined fluid jet / set of fluid jets radially adjacent the fourth collector). At 955, the correct part of the fluid jet arrangement is activated. The non-recyclable item is then propelled into the fourth collector, 975, then the item drops into a non-recyclable waste container, 985.

[0125] Once it is deemed that all the items are sorted, 995, the system ends, otherwise the system returns to step 920 wherein the mixed waste material is scanned with the camera.

[0126] In a particular example, method 900b is implemented on sorting device 100. Sorting device 100 has four segregation areas V1 -V4 wherein the first, second, third and fourth collectors can be located. The apparatus 200 shown in figure 4, incorporating the sorting device 100 would need to be modified to provide a passageway from each collector to each corresponding container.

[0127] Figure 1 1 c is a flow chart of a method 1000 for sorting waste material according to another example of the invention. The method 1000 may be implemented after the step of method 900a of moving an item into a collector for material, 960. The collector may be a collector of the collector arrangement. The method 1000 comprises collecting material of a first identified characteristic into a first collector, 1010. The method further comprises collecting material of a second identified characteristic into a second collector, 1020. When the first collector has reached or exceeded a first collector threshold filling level 1030, material of the first identified characteristic is transported into a first shredder, 1050. When the second collector has reached a second collector threshold filling level 1040, material of the second identified characteristic is transported into a second shredder, 1060. Shredded material of the first identified characteristic from the first shredder is further transported into a first container, 1070. Shredded material of the second identified characteristic from the second shredder is further transported into a second container, 1080.

[0128] Figure 11d illustrates example method steps for transporting material of the first or second identified characteristic into a first or a second shredder, respectively 1050, 1060. The method comprises rotating the support structure to align the first or second collector with an opening of the second collector such that material falls under gravity into the first or second shredder position, respectively 1090. In one example, transporting material of a second identified characteristic into a second shredder comprises rotating the support structure to align the second collector with an opening of the second collector such that material falls under gravity into the second shredder position.

[0129] In another example, the collector arrangement comprises a first collector and at least one second collector, each for a material of a different characteristic. The first shredder is configured to receive material from the first collector. The at least one second collector in this example are three second collectors namely second, third and fourth collector. The second shredder is configured to receive material from the second, third and fourth collector. This is achieved by rotating the support structure to align the second collector with an opening of the second collector such that material falls under gravity into the second shredder position. Figure 11d illustrates a preferred method step for transporting shredded material of a second identified characteristic into the second container from the second shredder 1080. The method comprises drawing under negative pressure material from the second shredder into a shredded material distribution device 1081 . The shredded material distribution device is translated into alignment with an opening of a corresponding second container, 1082. Shredded material is expelled from the shredded material distribution device upon alignment of the shredded material distribution device with the opening of the corresponding second container, 1083.

[0130] During the activation step of the fluid jet arrangement as per step 950 and 955 in method 900a, and steps 950a, 950b, 950c and 955 in method 900b, a force of the component can be adjusted based on the estimated mass of the item in order for the resulting force to move the item off the rotatable plate and into the aligned collector. For example, the force may be adjusted by adjusting a flow rate of fluid expulsion from the correct fluid jet of the fluid jet arrangement, or a flow rate of fluid suction of the fluid suction channel of the fluid suction arrangement. In some examples, the mass of the item can be estimated by the control system.

[0131] The development of an advanced plastic recycling system is essential to address the growing plastic waste problem. By leveraging cutting-edge technologies, the present invention offers a solution that enhances the efficiency and effectiveness of plastic recycling, contributing to a cleaner and more sustainable environment. Plastic waste from hospitals is particularly significant due to the extensive use of single-use items like medical devices, packaging materials, personal protective equipment, and disposable items. Challenges include contamination, segregation difficulties, high volume, and regulatory compliance.

[0132] The sorting device of the invention, and the associated apparatus thereof, allows for a compact design suitable for on-site sorting of mixed plastic waste, making it ideal for use in space-constrained environments such as hospitals. The invention is particularly effective in processing complex waste streams such as hospital waste, which includes a high volume of single-use plastic items.

[0133] The integration of advanced technologies such as infrared spectroscopy, artificial intelligence (Al), and machine learning (ML) automates and optimizes the sorting process, reducing the need for manual labour and minimizing errors. The control system, equipped with a camera and Al identification program, accurately identifies different grades of plastic, including PET, HDPE, PVC, LDPE, PP, and PS, ensuring precise sorting. By accurately identifying and sorting various types of plastics, the system increases recycling rates and reduces the amount of recyclable plastics being discarded. The Al module processes real-time images of the plastic items, making immediate predictions and sorting decisions, thereby enhancing the efficiency of the recycling process.

[0134] Moreover, the fluid jet arrangement of the invention, controlled by the control system, expels fluid to push items off the rotatable plate into the correct collector, ensuring accurate sorting based on identified characteristics, such as different recyclable plastic grades. The system can include means for estimating a mass of each item and can adjust the fluid flow rate, accordingly, providing the appropriate force to move items into the correct collector.

[0135] The apparatus can be integrated into larger material processing systems and scaled to meet varying waste processing needs. The apparatus is designed for easy operation and maintenance, with features such as a slider for easy removal and replacement of sorted material containers.

[0136] Any of the above-described features of the invention in relation to Figures 1a to 10 can be combined except where clearly incompatible.

[0137] Having described preferred examples of the invention it will be apparent to those skilled in the art that other examples incorporating the invention may be used. These and other examples of the invention illustrated above are intended by way of example only and the actual scope of the invention is to be determined from the appended claims.

Claims

PATENT CLAIMS1 . A material sorting device comprising: a rotatable plate comprising: a radially internal section having a radially outward negative gradient; and a radially external section having a radially outward positive gradient; thereby creating a trough between the internal section and the external section of the plate; a material removal module comprising at least one component for moving material radially outward across the rotatable plate; a support structure supporting the material removal module and rotatably supporting the rotatable plate; and a control system comprising: a camera configured to scan images of the material on the rotatable plate; an artificial intelligence identification module configured to identify, from the scanned images of the material: individual items; and a characteristic of each item, from a predetermined plurality of characteristics; wherein the control system comprises computer readable media with instructions that, when executed on a processor, performs the task for each identified item of: activating a component of the material removal module, dependent on the identified characteristic, to move the item of the identified characteristic off the rotatable plate at a predetermined rotational position.

2. The sorting device of claim 1 , wherein the camera has a predetermined fixed field of view of an area of the rotatable plate.

3. The sorting device of claim 2, wherein, to activate a component of the material removal module, dependent on the identified characteristic, the computer readable media of the control system has further instructions that, when executed on a processor, perform the tasks for each item of: scanning the item when it lies in the camera field of view; assigning the item with an ejection angle with respect to a frame of reference, wherein the frame of reference is a centre of the camera field of view; tracking a rotational position of the rotatable plate with respect to the frame of reference; and activating a corresponding component of the material removal module when the rotational position of the rotatable plate coincides with the ejection angle.

4. The sorting device of any of claims 1 to 3, wherein the radially outward negative gradient of the radially internal section is in the range of 10 to 20 degrees.

5. The sorting device of any of claims 1 to 4, wherein the radially outward positive gradient of the radially external section is in the range of 35 to 55 degrees.

6. The sorting device of any preceding claim, wherein the artificial intelligence identification module is further configured to estimate a mass of the item using the scanned image of the item; and the computer readable media of the control system has further instructions that, when executed on a processor, performs the task for each item of adjusting a force from the material removal module based on the estimated mass of the item.

7. The sorting device of any preceding claim, wherein the support structure further comprises a collector arrangement, the collector arrangement comprising: at least one collector for collecting material items from the rotatable plate, the at least one collector defined by an area radially outside the rotatable plate and an interior wall of the support structure.

8. The sorting device of any preceding claim, wherein the material removal module comprises a fluid jet arrangement disposed in the radial centre of the device, and the at least one component of the fluid jet arrangement comprises at least one fluid jet.

9. The sorting device of any preceding claim, wherein the material removal module comprises a robotic arm arrangement comprising at least one robotic arm disposed in the radial centre of the device, configured to extend and retract radially across the rotatable plate to urge material items into the at least one collector.

10. The sorting device of any of claims 7 to 9, wherein the collector arrangement comprises: a first collector for material of a first characteristic; and at least one second collector for material of a second characteristic; wherein the first collector and the at least one second collectors each are defined by distinct areas radially outside the rotatable plate and an interior wall of the support structure.11 . The sorting device of claim 10 when dependent on claim 8, wherein the at least one fluid jet of the fluid jet arrangement comprises at least two groups of fluid jets, a first group of fluid jets configured to expel fluid toward the first collector and a second group of fluid jets configured to expel fluid towards the second collector.

12. The sorting device of any of claims 7 to 11 , the support structure further comprising: a sensor arrangement comprising a corresponding sensor for each collector of the at least one collector for detecting a filling level of materials collected within the at least one collector; each of the at least one collector having an evacuation arrangement configured to evacuate material or material items collected within said collector; wherein the computer readable media of the control system has further instructions that, when executed on a processor, perform the tasks of:receiving a signal from the sensor arrangement that a filling level of the at least one collector has reached or exceeded a collector threshold filling level; and evacuating the material or material items collected within a collector by activating a corresponding evacuation arrangement.

13. A material processing apparatus for processing waste material comprising: the sorting device of any of claims 1 to 12, the material processing apparatus further comprising: a first shredder disposed within the material processing apparatus in a first position configured to receive material from the collector arrangement; and a first container connected to the first shredder for receiving shredded material from the first shredder.

14. The material processing apparatus of claim 13 comprising the sorting device of any of claims 10 to 12, further comprising: a second shredder disposed within the material processing apparatus in a second position configured to receive material from the at least one second collector; and at least one second container; wherein the second shredder is connected to a shredded material distribution device arranged to move adjacent an opening of each of the at least one second container to distribute shredded material from the second shredder to the at least one second container.

15. The material processing apparatus of claim 14, wherein the support structure is rotatable to an evacuation position; wherein the computer readable media of the control system has further instructions that, when executed on a processor, perform the tasks of: rotating the support structure to vertically align the at least one second collector with the second shredder before evacuating the material ormaterial items within a collection area by activating a corresponding evacuation arrangement.

16. The material processing apparatus of any of claims 14 or 15, wherein the at least one second container comprises at least two second containers; wherein the shredded material distribution device comprises a retaining member for retaining the shredded material; and wherein the computer readable media of the control system further comprises instructions that, when executed on a processor, performs the task of: based on the characteristic of the shredded material, selecting a corresponding second container from the at least two second containers; aligning the shredded material distribution device with the selected second container; and actuating a release of the retaining member upon alignment of the shredded material distribution device with the corresponding container to release the shredded material.

17. The material processing apparatus of any of claims 14 to 16, wherein the shredded material distribution device comprises a pump arrangement for creating a negative pressure gradient between the second shredder and the shredded material distribution device.

18. The material processing apparatus of any of claims 13-17, wherein the first shredder is arranged to create a negative pressure gradient along a first shredder output as seen downstream from the first shredder to the first container.

19. The material processing apparatus of any of claims 14 to 18, the collector arrangement further comprising a waste collector for waste material, the material processing apparatus further comprising: a waste container disposed within the sorting device in a third position configured to receive material from the waste collector.

20. The material processing apparatus of any of claims 14 to 19, further comprising a rail to which the shredded material distribution device is translatably supported, configured to allow a horizontal movement of the shredded material distribution device above each of the at least second containers, in an in-use orientation.21 . The material processing apparatus of any of claims 13 to 20, further comprising: a supply material conveyor for transporting material to the rotatable plate; and wherein the control system is further configured to control an operation of the supply material conveyor dependent on available space on the rotatable plate.

22. A method for sorting material using the material processing apparatus of any of claims 13 to 21 , comprising: feeding material onto the rotating rotatable plate; scanning a predetermined field of view of the rotating rotatable plate with the camera; processing the corresponding scanned image of the field of view with the artificial intelligence identification module to identify: individual items; and a characteristic, from a predetermined plurality of characteristics, of each item identified; and for each item, activating a component of the material removal module, dependent on the identified characteristic, to move the item off the rotating rotatable plate at a predetermined rotational position of the item with respect to a fixed frame of reference.

23. The method of claim 22, wherein the component is a fluid jet and the material removal module is a fluid jet arrangement, wherein the activating a component of the material removal module dependent on the identified characteristic to move the item off the rotating rotatable plate at a predeterminedrotational position of the item with respect to a fixed frame of reference, comprises expelling fluid, thereby pushing the item off the rotating rotatable plate.

24. The method of claim 22 or 23, wherein activating a component of the material removal module dependent on the identified characteristic for each item comprises: assigning the item with an ejection angle with respect to the fixed frame of reference, wherein the frame of reference is a centre of the camera field of view; tracking a rotational position of the rotatable plate with respect to the frame of reference; and activating the corresponding component of the material removal module when the rotational position of the rotatable plate coincides with the ejection angle.

25. The method of any of claims 22 to 24, further comprising: estimating a mass of the item by further processing of the corresponding scanned image with the artificial intelligence identification module; adjusting a force of the component, based on the estimated mass of the item, to a force to move the item off the rotating plate and into an aligned collector.

26. The method of any of claims 22 to 25, further comprising: collecting material of a first identified characteristic into a first collector collecting material of a second identified characteristic into a second collector when the first collector has reached or exceeded a first collector threshold filling level, transporting material of the first identified characteristic into a first shredder when the second collector has reached a second collector threshold filling level, transporting material of the second identified characteristic into a second shredder further transporting material of the first identified characteristic into a first containerfurther transporting material of the second identified characteristic into a second container.

27. The method of claim 26, wherein transporting material of the second identified characteristic into a second shredder comprises rotating the support structure to align the second collector with an opening of the second collector such that material falls under gravity into the second shredder position.

28. The method of claim 26 or 27, wherein further transporting material of a second identified characteristic into the second container from the second shredder comprises: drawing under negative pressure material from the second shredder into a shredded material distribution device translating the shredded material distribution device into alignment with an opening of a corresponding container expelling shredded material from the shredded material distribution device upon alignment of the shredded material distribution device with the opening of the corresponding container.

29. The device of any of claims 1 to 12, the apparatus of any of claims 13 to 21 , or the method of any of claims 22 to 28, wherein the plurality of characteristics comprises a plurality of plastic grades.

Images