Plastic recycling begins with accurate separation of mixed waste into pure polymer streams. A well‑balanced sorting line not only boosts material recovery but also delivers higher‑value recyclate. However, the capital cost of plastic sorting equipment can vary widely, reflecting differences in technology, capacity, and customization. This guide breaks down the main factors that influence price, typical cost ranges, and real‑world considerations for selecting the right equipment.
Sorting Technology
Manual Pre‑Sort Stations (tables and workstations): $5,000–$15,000 per station.
Trommel and Vibratory Screens: $20,000–$100,000 depending on drum size and wear‑resistance features.
Air Classifiers: $10,000–$60,000; higher‑capacity blowers and adjustable gates add to cost.
Density Tanks (Float‑Sink): $50,000–$200,000 per tank; multi‑stage systems incur additional pumps and control panels.
NIR Optical Sorters: $150,000–$450,000 per unit. High‑speed lines with 3,000+ items/min capacity command top dollar.
Color/Shape Cameras: $80,000–$250,000, often sold as add‑ons to NIR machines.
Electrostatic Separators: $60,000–$180,000, dependent on capacity (0.5–3 t/h) and electrode configuration.
Ballistic Separators: $40,000–$120,000 for 2–6 t/h models; anti‑wrap rotors and stainless‑steel decks cost more.
XRT Sorters: $300,000–$800,000, niche devices for detecting chlorine‑based polymers like PVC.
Capacity and Throughput
Equipment is often priced per tonne per hour (tph). A basic NIR unit rated at 1 tph may start around $150,000, while a high‑capacity
5 tph machine can reach $450,000. Modular designs allow you to “stagger” investment—starting small ($200–$300 per daily kg) and expanding to $100–$150 per daily kg at scale.
Automation and Control
Standalone Machines with manual controls: base price.
PLC/SCADA Integration: +10–20% for touch‑screen HMI, remote diagnostics, and data logging.
IIoT Connectivity: +5–10% for cloud‑based dashboards tracking throughput, purity, and downtime.
Material Handling & Feeding
Conveyors & Feeders: $10,000–$50,000 depending on length, speed control, and hygienic design.
Buffer Hoppers and Surge Bunkers: $5,000–$25,000 to ensure consistent material flow.
Elevators and Chutes: $3,000–$15,000 based on height and wear‑resistant liners.
Structural & Environmental Requirements
Custom Frames and Enclosures: +$5,000–$30,000 for stainless steel, dust‑proofing, or wash‑down ratings.
Ventilation, Dust Collection & Noise Abatement: $10,000–$60,000 depending on local regulations and plant layout.
After‑Sales Service and Warranty
Standard Warranty (12 months parts): included.
Extended Warranty & Service Packages: 5–15% of equipment cost per year.
Spare Parts Kits: $2,000–$10,000 tailored to blade sets, belts, sensors, and filters.
| System Type | Capacity (tph) | Estimated Cost Range (USD) |
|---|---|---|
| Basic Pre‑Sort + Trommel + Air Classifier | 🌐 1–3 | $60,000–$180,000 |
| Standard Line: Shredder + Wash + Float‑Sink | 🌐 3–6 | $250,000–$450,000 |
| Advanced: + NIR + Color Sorter | 🌐 6–12 | $550,000–$1,200,000 |
| High‑End: Full Multi‑Stage + XRT + IIoT | 🌐 12–20+ | $1,200,000–$3,000,000 |
Note: Prices vary by region, currency exchange, and supplier.
Modular Skids allow phased investment:
Phase 1: $200,000 for 2 tph (shred + float‑sink).
Phase 2: +$300,000 to add NIR and air classifier (total 5 tph).
Plug‑and‑Play Upgrades: Add a second NIR head ($120,000) to double optical sorting throughput.
Turnkey vs. Line‑By‑Line: Complete turnkey lines cost ~10–15% less than buying individual machines separately, due to reduced engineering and installation fees.
Mid‑Size European MRF (5 tph)
Equipment: Trommel + Air Classifier + NIR + Pelletizer
Investment: €650,000 (~$700,000)
ROI: 2.5 years through sale of food‑grade PET and energy savings.
North American Packaging Scrap Facility (3 tph)
Equipment: Shredder + Wash Line + Float‑Sink + Color Sorter
Investment: $420,000
ROI: 18 months by feeding recycled PP back into injection molding.
Asian Bottle‑Only Line (8 tph)
Equipment: Dual NIR heads + Ballistic + Electrostatic + Wash
Investment: $1,100,000
ROI: 3 years; annual energy recovery reduces electric bill by $80,000.
Get Multiple Quotes from OEMs with different technology specializations.
Site Visits: Touring operating facilities reveals hidden costs (foundation work, piping).
Total Cost of Ownership (TCO): Factor in energy use (kWh/t), maintenance intervals, and spare parts pricing.
Leasing & Financing: Many suppliers offer 5‑year equipment loans with 0–3% interest, easing upfront capital constraints.
Operator Training (often $5,000–$10,000) reduces mis‑sort rates by up to 20%.
Routine Calibration: Annual NIR sensor checks cost ~$2,000 but maintain peak accuracy.
Preventive Maintenance Contracts: 4 visits per year for blade swaps, belt tensioning, and software updates.
Investing in plastic sorting equipment requires careful alignment of technology, capacity, and budget. By understanding how different machine types—and their associated costs—interact within a full sorting line, you can build an efficient, scalable solution that maximizes material recovery and return on investment. Thoughtful planning around modular expansion, after‑sales support, and process optimization ensures your facility remains competitive as recycling markets evolve.
For personalized guidance and a detailed quotation, please contact us.