PLC-Controlled Intelligent Conveyor System with AI-Enhanced Vision for Efficient Waste Sorting

• DOI: 10.3390/app15031550
• Publication Date: 2025-02-03T17:18:56Z
• Authors: Natheer Almtireen; Viraj Reddy; Max Sutton; Alexander Nedvidek; Caden Karn; Mutaz Ryalat; Hisham Elmoaqet; Nathir Rawashdeh
• Keywords: Conveyor system

Current waste sorting mechanisms, particularly those relying on manual processes, semi-automated systems, or technologies without Artificial Intelligence (AI) integration, are hindered by inefficiencies, inaccuracies, and limited scalability, reducing their effectiveness in meeting growing management demands. This study introduces a prototype machine that integrates an AI-driven vision system with Programmable Logic Controller (PLC) for high-accuracy automated sorting. The system, powered the YOLOv8 deep learning model, achieved accuracies of 88% metal cans, 75% paper, 91% plastic bottles, overall precision 90%, recall 80%, mean average (mAP50) 86%. provides real-time classification, while PLC manages conveyor actuator operations to ensure seamless Experimental results controlled environment validate system’s high accuracy, minimal processing delays, scalability industrial recycling applications. innovative integration AI automation enhances efficiency, reduces ecological impacts, minimizes labor dependency. Furthermore, aligns sustainable practices, promoting circular economy principles advancing Sustainable Development Goals (SDGs).