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.
1. Key Factors Influencing Equipment Cost
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Sorting Technology
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Manual Pre‑Sort Stations (tables and workstations): $5,000–$15,000 per station.
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Trommel and Vibratory Screens: $20,000–$100,000 depending on drum size and wear‑resistance features.
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Air Classifiers: $10,000–$60,000; higher‑capacity blowers and adjustable gates add to cost.
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Density Tanks (Float‑Sink): $50,000–$200,000 per tank; multi‑stage systems incur additional pumps and control panels.
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NIR Optical Sorters: $150,000–$450,000 per unit. High‑speed lines with 3,000+ items/min capacity command top dollar.
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Color/Shape Cameras: $80,000–$250,000, often sold as add‑ons to NIR machines.
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Electrostatic Separators: $60,000–$180,000, dependent on capacity (0.5–3 t/h) and electrode configuration.
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Ballistic Separators: $40,000–$120,000 for 2–6 t/h models; anti‑wrap rotors and stainless‑steel decks cost more.
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XRT Sorters: $300,000–$800,000, niche devices for detecting chlorine‑based polymers like PVC.
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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
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Standalone Machines with manual controls: base price.
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PLC/SCADA Integration: +10–20% for touch‑screen HMI, remote diagnostics, and data logging.
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IIoT Connectivity: +5–10% for cloud‑based dashboards tracking throughput, purity, and downtime.
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Material Handling & Feeding
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Conveyors & Feeders: $10,000–$50,000 depending on length, speed control, and hygienic design.
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Buffer Hoppers and Surge Bunkers: $5,000–$25,000 to ensure consistent material flow.
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Elevators and Chutes: $3,000–$15,000 based on height and wear‑resistant liners.
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Structural & Environmental Requirements
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Custom Frames and Enclosures: +$5,000–$30,000 for stainless steel, dust‑proofing, or wash‑down ratings.
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Ventilation, Dust Collection & Noise Abatement: $10,000–$60,000 depending on local regulations and plant layout.
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After‑Sales Service and Warranty
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Standard Warranty (12 months parts): included.
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Extended Warranty & Service Packages: 5–15% of equipment cost per year.
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Spare Parts Kits: $2,000–$10,000 tailored to blade sets, belts, sensors, and filters.
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2. Typical Price Ranges by System Configuration
| 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.
3. Customization and Modular Expansion
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Modular Skids allow phased investment:
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Phase 1: $200,000 for 2 tph (shred + float‑sink).
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Phase 2: +$300,000 to add NIR and air classifier (total 5 tph).
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Plug‑and‑Play Upgrades: Add a second NIR head ($120,000) to double optical sorting throughput.
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Turnkey vs. Line‑By‑Line: Complete turnkey lines cost ~10–15% less than buying individual machines separately, due to reduced engineering and installation fees.
4. Real‑World Case Studies
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Mid‑Size European MRF (5 tph)
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Equipment: Trommel + Air Classifier + NIR + Pelletizer
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Investment: €650,000 (~$700,000)
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ROI: 2.5 years through sale of food‑grade PET and energy savings.
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North American Packaging Scrap Facility (3 tph)
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Equipment: Shredder + Wash Line + Float‑Sink + Color Sorter
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Investment: $420,000
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ROI: 18 months by feeding recycled PP back into injection molding.
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Asian Bottle‑Only Line (8 tph)
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Equipment: Dual NIR heads + Ballistic + Electrostatic + Wash
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Investment: $1,100,000
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ROI: 3 years; annual energy recovery reduces electric bill by $80,000.
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5. Budgeting Tips for Buyers
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Get Multiple Quotes from OEMs with different technology specializations.
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Site Visits: Touring operating facilities reveals hidden costs (foundation work, piping).
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Total Cost of Ownership (TCO): Factor in energy use (kWh/t), maintenance intervals, and spare parts pricing.
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Leasing & Financing: Many suppliers offer 5‑year equipment loans with 0–3% interest, easing upfront capital constraints.
6. Ensuring Long‑Term Performance
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Operator Training (often $5,000–$10,000) reduces mis‑sort rates by up to 20%.
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Routine Calibration: Annual NIR sensor checks cost ~$2,000 but maintain peak accuracy.
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Preventive Maintenance Contracts: 4 visits per year for blade swaps, belt tensioning, and software updates.
Conclusion
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.
Comments(14)
This guide is super helpful for our recycling plant planning. The price breakdowns are exactly what we needed to compare options.
Seriously considering the modular approach for our facility. Staggering the investment makes so much sense financially.
Wow, didn’t realize NIR sorters could get that expensive! The $800K range kinda shocked me tbh.
Anyone have real experience with those XRT sorters? The cost seems steep but if it helps with PVC detection…
The ROI examples are gold. Seeing the 18-month payback period case study makes me more confident about this investment.
Material handling costs seem low compared to the main equipment. That’s a pleasant surprise.
Kinda wish there was more detail on maintenance costs. Those hidden expenses can really add up.
That European MRF case study is impressive. 2.5 year ROI is better than I expected for mid-size operations.
The leasing option mentioned at end could be a game changer for smaller recyclers. Good to know!
How often do these prices get updated? With inflation lately, I wonder if these ranges still hold.
The IIoT connectivity add-on costs seem totally worth it for the data tracking benefits. No brainer imo.
Shredder + wash line combo at $420K sounds like sweet spot for our operation. Gonna request quotes ASAP.
Wish there was more about operating labor costs though. High-tech equipment still needs skilled operators right?
The energy savings numbers from that Asian case study are insane! $80K annual reduction makes the investment easier to swallow.