Sortera Technologies, based in Markle, Indiana, is differentiating itself in the aluminum sorting market by not just providing sorting equipment but by owning and operating its own sorting facilities. This hands-on approach contrasts with the typical model, where equipment manufacturers sell or license their technologies. Instead, Sortera’s strategy revolves around operating sorting plants that use advanced sensors, artificial intelligence (AI), and data analytics to handle complex aluminum scrap, including materials like twitch, tweak, and zorba.
AI and Advanced Sensors to Maximize Sorting Efficiency
At the heart of Sortera’s operation is its AI-powered sorting technology, which uses multiple sensors to gather 20 to 30 data points per piece of material. These data points include critical information like size, density, chemical classification, and product form (wrought or cast material). This sophisticated system allows Sortera to make highly accurate, repeatable sorting decisions, ensuring high-quality outputs. Throughput rates can reach up to 5 to 8 tons per hour, which is ideal for handling mixed aluminum fractions.
The sorting process begins with material sizing, followed by independent feed systems that optimize material flow through the technology. The system uses a vision system to classify the form of the material first, which in turn helps determine the most appropriate chemical classifier. This method ensures that the sorting process is both efficient and precise, maximizing material value and minimizing losses.
Expanding Capabilities: Moving Beyond Twitch to Tweak and Zorba
Sortera started by processing twitch—a mixed aluminum fraction derived from post-auto shredder systems—but has since expanded its operations to include tweak and zorba. Tweak refers to shredded aluminum that comes from electronic products, and zorba is a more complex mixture of nonferrous metals like aluminum, copper, and zinc. Although Sortera has yet to process zorba at a mass production level, it plans to do so within the next 18 to 24 months. The company is also working on upgrading cast aluminum alloys, such as the development of 380, 356, and 319 alloys, ensuring it can meet the demands of aluminum mills that require higher-quality, near-specification scrap.
Future Growth Plans: New Plants and Strategic Partnerships
Sortera’s growth plans include building two new sorting plants in the Southeast U.S. in 2025, each capable of processing 120 million pounds of scrap annually. These new plants will focus on end-of-life aluminum material, which Sortera will purchase directly. In addition to the existing tolling partnership with Novelis, Sortera is exploring collaborations with other major aluminum consumers, including rolling mills, extrusion billet casters, and the die-cast industry.
The Southeast U.S. is a strategic location for Sortera, as it is home to a large concentration of aluminum rolling mills and abundant scrap material.
Market Implications: Shifting Demand for Scrap and Sorting Technology
As aluminum melting capacity expands in the U.S., the demand for specific scrap grades will likely shift, with previously less competitive grades becoming more desirable. This evolving market will push aluminum mills to invest in sorting technologies or form strategic partnerships to meet quality requirements for domestic scrap. Sortera’s innovative approach places it in a strong position to capture market share, especially as mills increasingly seek to source higher-quality, domestic scrap material.
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