Sortera Technologies doubles capacity with Tennessee facility, using AI-Powered sorting for high-purity recycled aluminium

USA – Sortera Technologies has brought its second processing facility in Lebanon, Tennessee, online, doubling annual capacity to 240 million lbs (approximately 109,000 tonnes) using AI-driven sorting to transform mixed alloy scrap into high-value materials.

The facility is moving into full operational status this month, responding to surging demand for high-purity, sustainably sourced aluminium alloys and securing a resilient domestic supply chain for American manufacturers. 

The launch marks a pivotal milestone for Sortera, which has been scaling its upcycling platform since the success of its flagship Markle, Indiana facility. 

The Lebanon facility produced sellable, high-purity material within its first week of operation, demonstrating the maturity of the company’s AI-powered platform.

AI-Powered Sorting at Scale

Traditional scrap sorting relies on manual picking, magnetic separation, and eddy current systems, which cannot distinguish between different aluminium alloys (e.g., 6061 vs. 7075) that have different metallurgical properties. 

Sortera’s system uses laser-induced breakdown spectroscopy (LIBS), computer vision, and machine learning to identify the specific alloy composition of each piece of scrap on a moving conveyor. 

High-value applications, aerospace forgings, automotive structural components, require specific alloys; mixing them compromises mechanical properties. 

By sorting mixed scrap to alloy-specific purity, Sortera produces feedstock that can be directly remelted into new high-performance products without the energy penalty of refining.

Doubling Capacity, Halving Imports

The 240 million lbs annual capacity represents a significant addition to domestic recycled aluminium supply. 

The facility is positioned in the “Battery Belt” and the Southern automotive manufacturing corridor, close to electric vehicle and battery plants that are among the largest consumers of aluminium. 

Recycling aluminium uses approximately 95 percent less energy than virgin production, generating a massive reduction in CO₂ footprint for Sortera’s partners and supporting their 2030 and 2040 sustainability goals. 

By providing high-quality recycled content directly to regional manufacturers, Sortera reduces transport emissions and costs.

From Mixed Scrap to Premium Feedstock

Michael Siemer, CEO of Sortera Technologies, explained that the performance of the Markle facility proved there is strong appetite for sustainable, high-quality recycled aluminium. 

By bringing the Lebanon operation online, Sortera is meeting that demand head-on, effectively doubling capacity and providing a streamlined, localised supply chain for regional customers. 

Optimising high-speed sorting lines ensures partners receive the highest purity feedstock with maximum efficiency and minimal environmental impact. 

Ben Pope, COO of Sortera Technologies, added that the Lebanon facility represents the next evolution of the company’s operational footprint, building a more robust, domestic infrastructure that can support the rapid growth of sustainable manufacturing in North America.

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