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About KORN Recycling
KORN Recycling GmbH is one of the leading technology providers in the German circular economy and a specialist in the processing of substitute fuels (EBS). The family-owned company operates a sorting facility for industrial and commercial waste in Albstadt.
The facility in Albstadt:
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Input material: Mixed industrial and commercial waste
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Throughput: Around 100,000 tons per year
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Focus: High-quality EBS production for the cement and power plant industries
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Operation: Upgrade by X.Sort in June 2025
The starting point: A powder keg of batteries
Sorting commercial waste is a high-risk business. At KORN Recycling, the danger posed by improperly disposed lithium-ion batteries was ever-present: battery-related fires broke out at the facility every week.
The history of the Albstadt site underscores the severity of the situation: as early as 2009, the entire facility burned to the ground following a fire. In addition to operational risks, waste management companies today face another existential threat: since 2004, insurance premiums for sorting facilities have increased eightfold. Conventional sensor technology is unable to detect the small, often hidden fire hazards in the massive material flow of 100,000 tons per year in time.
“Our facility has experienced several fires in the past, most of which were caused by improperly disposed lithium-ion batteries.”
Alexander Korn, Managing Director of KORN Recycling
The solution: X.Sort
To eliminate the risk of fire at KORN Recycling at its source, X.Sort was integrated into the main stream immediately after the pre-shredder. Where conventional optical sensors fail due to contamination or obstruction, X.Sort utilizes a powerful combination of technologies:
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X-ray technology: Fully scans the material flow—regardless of contamination or concealment.
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Real-time AI: Detects even the smallest lithium-ion batteries, battery-powered devices, and damaged elements in milliseconds.
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Deep learning: Identifies incendiary devices even under heavy layers of waste or inside sealed plastic bags.
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Precise ejection: Fully automatic separation of hazardous materials at full conveyor belt speed.
Results and achievements since the system went live
X.Sort has been operating in two-shift operation at Korn Recycling since mid-June 2025. The system identifies devices and rechargeable batteries in milliseconds and removes them automatically from the main stream before they can be subjected to mechanical stress.
The result is a dramatic reduction in fire risk while maintaining a consistently high throughput.
Der X.Sort wirft auch schwere Elektrogeräte, wie Laptops, problemlos bei KORN Recycling aus.
Ein Akkupack wird ebenso regelmäßig bei KORN Recycling ausgeworfen.
Diese Bandbreite an Elektrogeräten wird regelmäßig bei KORN Recycling dank dem X.Sort gefunden.
Der X.Sort wirft auch schwere Elektrogeräte, wie Laptops, problemlos bei KORN Recycling aus.
“With X.Sort from WeSort.AI, we can now identify and eliminate potential hazards early on, before they lead to a fire.”
Alexander Korn, Managing Director of KORN Recycling
Technical details and system configuration
The X.Sort solution was specifically developed for use in challenging conditions. In commercial waste sorting at Korn, the system handles massive material flows and identifies potential hazards where conventional sensorics reach their limits.
Key features
Deep learning AI
Detection of batteries and electronic waste buried under up to 50 cm of material.
Heavy-duty discharge
Reinforced nozzle bar for heavy objects (up to 9 kg).
Technology fusion
A combination of X-ray technology and AI for a “peek inside the material.”
Technical specifications
Active conveyor width: 1.5 m
Conveyor speed: up to 4 m/s
X-ray technology: Certified full-protection system (Level 1 radiation protection)
Why the investment pays off
KORN Recycling demonstrates why modern sensor technology is an economic necessity today. In an industry where insurance premiums have risen eightfold since 2004, our X.Sort system provides the key solution: So that fire safety becomes a cost-effective precaution for people and the environment.
Preventing damage
The system saves an average of €200,000 per year in costs related to minor fire damage, firefighting operations and outage work.
Protection of tangible assets
This investment effectively protects tangible assets from total loss.
Full compliance
The removed batteries are safely placed in fireproof containers and can be directly fed into the WEEE recycling process.
“At KORN, our deep learning algorithms achieve a level of precision that far exceeds what conventional sensors are capable of. By continuously training our AI on-site, we not only safeguard the plant but also increase the value of the entire material flow.”
Nathanael Laier, Co-Founder and CEO at WeSort.AI
The success at KORN Recycling demonstrates that the technology for fire-safe and highly efficient sorting is ready for widespread use. The system, which recovers around 12.5 kg of electronic waste per hour from the waste stream in Albstadt, can be scaled up in a modular fashion to fit virtually any existing facility.
Eliminate fire hazards in your facility. Let’s work together to plan your X.Sort solution.
Contact options
Telephone
Adress
WeSort.AI GmbH
Leightonstraße 3
97074 Würzburg