On this episode, Abate travels to Denver, Colorado, to gain exclusive insights into the future of recycling as he sits down with Joe Castagneri, a leading expert in AI and robotics at Amp Robotics. As Materials Recovery Facilities (MRFs) process an astonishing 25 tons of waste per hour, robotic sorting emerges as the definitive solution for the long term.
Recycling is a for-profit business. What happens when margins don’t align with recycling efforts is that valuable electronic waste remains unrecovered? Amp’s innovative approach to leveraging robotics and AI in recycling has a profound impact, driving down costs and increasing the volume of devices that can be efficiently sorted for processing.
Joe Castagneri earned a Master’s degree in Applied Mathematics and an undergraduate degree in Physics upon graduation. While pursuing a degree, he initially joined Amp Robotics’ team in 2016, where he collaborated on developing machine learning models to identify recyclables within video feeds from Materials Recovery Facilities (MRFs). As we converse, Matt is spearheading innovation as Head of AI at Amp Robotics, revolutionizing the recycling industry by leveraging automation to reshape its economic landscape.
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Welcome to Robohub. As we converse in Denver, Colorado, I’m joined by Joe Castagneri, leader of AI initiatives at Amp Robotics. The astonishing efficiency of modern waste management systems is exemplified by the fact that Materials Recovery Facilities (MRFs) can process up to 25 tons of trash per hour, highlighting the remarkable capacity and speed at which these facilities can transform discarded materials into valuable resources. Despite advancements in technology, much of this process remains labor-intensive and manual. Amp Robotics is convinced that a robotic-driven approach will revolutionize its industry. I first learned about Amp Robotics when I was working at a startup accelerator in Boston. They were one of the portfolio companies, and I was impressed by their mission to reduce waste and promote sustainability through robotics.
While still a student at CU Boulder, I was introduced to Matan Horowitz, the company’s founder, at the age of 19, when my academic pursuits involved significant math applications. Amp Robotics was still in its nascent stages, exploring the potential of sorting systems using an Xbox Kinect sensor in early experiments. Following a captivating presentation on robotics and recycling, I embarked on an internship in 2016, subsequently transitioning to machine learning by 2019.
Fascinating. Is the corporation’s foundation rooted in artificial intelligence technology?
Precisely. The primary objective was to converge cutting-edge technologies in robotics, artificial intelligence, and emerging tech to tackle pressing social concerns effectively. Matan recognized recycling as a key challenge for our technology to tackle.
With breakthroughs in graphics processing unit technology, would you have begun leveraging cloud computing capabilities from the outset?
Indeed, we chose edge computing due to inadequate internet connectivity in our waste management services and the imperative need for real-time processing. As our business evolved, we leveraged Google Cloud’s scalability and reliability by migrating certain support functions.
As a pioneer in artificial intelligence (AI) and robotics, Amp Robotics has undergone significant transformations since its inception. Initially founded in 2013 by Ryan Johnston and Bryce Simon, the company’s primary focus was on developing AI-powered recycling technology for sorting recyclables from mixed waste streams.
Through reflecting on our mistakes and learning from past experiences. Robots deployed in various settings have consistently provided valuable learning experiences. Rapidly iterating on insights and grasping customer needs have been crucial. Waste management’s greatest challenge arises from the inherent unpredictability and diversity of waste streams.
Completely. Recycling services effectively manage the diverse array of discarded electronic devices that enter their facilities daily.
Certainly. Consider a milk container – its appearance can vary substantially. Conventional laptop vision falters in this environment. With thorough examination and sufficient understanding, even the most intricate complexities are manageable.
As the industry of packaging supplies and designs undergoes constant transformation. The AI seamlessly integrates these adjustments into its processing framework ensuring a consistent output.
Constant retraining and adaptation are the bottom line. As industry dynamics shift and market demands fluctuate, our fashion strategies require ongoing adaptation to remain relevant. Maintaining a well-manicured mannequin is crucial in today’s dynamic retail landscape.
The company appears to be struggling with significant model drift, which may hinder its ability to accurately forecast future trends and make informed decisions.
Sure. How can we streamline this concise expression? Completely agree.
Here, just beyond you, lies our latest development – not a prototype, but rather a fully functional mock-up of the final product.
Sure. So, our flagship Cortex product features a delta-fashion robot that can effortlessly span across a conveyor belt. The belt will depart from the location where I am standing right here. We are currently located on our manufacturing floor, where we produce the very products we assemble. We integrate Omron robots, followed by customised design of pneumatics, wiring, body, and vision cabinet operating edge compute. We collectively consolidate all of this information into a comprehensive package deal. Materials in process can seamlessly transition onto a conveyor belt for direct transport to a recycling facility.
Yeah. This outdated prototype, known as Claudia, is roughly five or six years old. To confirm, you’re discussing a suction cup gripper paired with a robust spring, designed to adapt to varying fabric peaks or situations by mechanical absorption.
As the pneumatic system activates, the explicit gripper and suction cup work in tandem to establish a secure vacuum seal, allowing us to descend safely, followed by the controlled release of air pressure that enables us to dismount onto the side of the belt and enter a chute or bunker.
In such cases, this designated spot would accommodate a milk container, securely holding it in place.
Sure. The air suction system, situated ahead of the robotic cell, employs a digital camera to monitor the conveyor belt and identify the fabric’s location and type. Following configuration, the software will narrow its focus to only consider the specific parameters it’s been designed to process. Proper. Following this period, there are so many challenges to address that I don’t have the bandwidth for them. To maximize the range of options available for decision-making within my designated scope, considering their potential length and complexity is crucial. Once I arrive at this location, I’ll ensure my presence coincides with the designated time, after which I’ll turn on my vacuum immediately. After securing the buckle, remove it from the facet of the belt.
Actually, the captivating aspect here is that this can be a dynamic and transforming serpentine belt. You’ve been allotted a limited timeframe and are striving to reach a specific quota of devices per minute that you’re selecting.
Sure. Proper. The inherent value proposition of these items lies in their ability to serve as a substitute for human sorters. At peak performance, human sorters will process materials at an astonishing rate of 30 to 50 picks per minute. A well-designed robotic system can process materials at a rate of 30-50 picks per minute, matching the efficiency of a skilled human worker. But what if you could push its capabilities even further? These programs consistently achieve an impressive pace of 80-plus picks per minute. As they consistently surpass the 100-mark when the fabric stream provides an extensive range of suitable options in a well-structured manner. Before an individual, machinery operates consistently and efficiently throughout two consecutive daily shifts, without interruption or pause.
The manner in which processes evolve across facilities often hinges on factors such as regulatory requirements, industry norms, and organisational preferences. The applications of these technologies extend beyond their primary use cases to benefit various industries and organizations, enabling diverse corporations to streamline operations, enhance efficiency, and drive innovation.
Dramatically. Sure. There is always a conveyor belt present in a facility. That’s the final probability Conveyor. And it’s the final one. Is this a desperate warning or a harsh reality? The fate of discarded items hangs precariously in the balance – will they find new life, or succumb to the abyss of waste? While some may view recycling as a convenient solution, others might find it an annoying aspect of shopping given that you ultimately decide where it goes – into the recycling bin, with the understanding that everything will indeed be recycled. Regardless of the outcome at this facility, our intention is to successfully extract whatever resources are available, leveraging its capabilities to achieve our goals. The remainder goes to landfill. So far, we’ve focused on populating the probability distributions with relevant data, ensuring a comprehensive overview of the possibilities? While traditional sorting methods may yield varying results, a unique utility is likely to be the separation of 2D paper and cardboard from 3D containers and plastics, which presents its own set of challenges due to the conventional sorting process’s inability to fully resolve these issues. And to ensure high-quality management, you’ll need to extract relevant information from that data stream. Historically, this process has typically been handled on a personal basis. If the process isn’t completed, there’s a high likelihood that the client will reject your paper bales. The product contains an unacceptably high volume of plastic contaminants and impurities. To ensure the value of the final product, namely a paper, it is crucial that all necessary steps are taken throughout its development process. They will serve as key components of a high-quality management system designed to seamlessly streamline.
Are contaminants and non-recyclable materials still making their way to Materials Recovery Facilities (MRFs), compromising the entire recycling stream? Who? As you’re sorting through the debris, carefully distinguishing between recyclables like paper, plastic, and cans, and then addressing the miscellaneous waste that people carelessly discarded alongside them.
That’s precisely proper. I’m going one step additional. What unique treasures lie hidden within the waste stream, waiting to be unearthed and transformed into something of value? Valuable metals and hydrocarbons have been received, as well as unprocessed paper and wooden goods, but the challenge lies in their lack of refinement. When opportunities arise, your ability to mentor others can bring added value. It’s trash until we’re able to clean it, at which point it transforms into something valuable. What will become of this material? It’s not trash. The space has been transformed into a thriving entrepreneurial hub. When people dispose of items in recycling bins, they often take it for granted that their efforts will contribute to solving environmental problems, wondering, “I’m sure they’ll find a use for this.”
At the recycling facility, the material is unloaded from the collection truck and deposited onto a massive pile of mixed recyclables. A high-capacity entrance loader then scoops up a batch of the contents and transfers them to the processing system. Within the system, the primary conveyor belt operates as the Presort line, serving as a central component. The facility’s sprawling sorting system features an extensive conveyor belt, where diligent workers carefully extract valuable items from the steady stream of products, including rare finds like bicycles. As a result, this task requires personal attention due to its complex and self-serving nature. Removing unconventional items such as wayward bowling balls, canine feces bags, and oversized objects like bicycles or mattresses, which can potentially compromise equipment functionality in the long run.
The following are common types of standard sorting tools:
To recycle a mattress effectively, the first step is to cut it down to size, usually by removing any handles or straps that may be attached. Next, use specialized equipment designed specifically for mattress recycling – known as mattress compactors – which are able to compress and crush the mattresses into smaller pieces. These compactor machines can reduce the volume of a mattress by up to 90%, making it easier to transport and process. The crushed mattresses can then be sorted by material type, such as foam, fabric, or steel coils, before being sent to facilities for further processing and eventually transformed into new products like carpets, clothing, or even new mattresses.
In urban areas, the recycling dumpsters are typically located. On my construction site, for example, we have designated dumpsters for waste disposal and another specifically designed to accommodate single-stream recyclables. People will stash their obsolete IKEA lamp inside because of its metal content. They assume it’ll be recycled. Despite waste being largely invisible in everyday life, consumers often neglect the reality that efficient waste management requires a significant throughput of around 25 tons per hour to be economically viable. With no option to delay, they won’t disassemble the lamp. It stands as a crucial factor in enhancing effectiveness.
25 tons an hour.
That’s widespread for municipal services. In Denver, for instance, a typical facility might process 25 tons per hour, or approximately 50,000 kilograms, of fabric.
According to various estimates, the average American generates approximately 4.4 pounds of waste per day, which translates to around 1,605 pounds annually?
The average American household generates around 102,000 pounds of trash each year, which is roughly equivalent to 3-4 tons of waste. Approximately one ton of materials are recyclable.
So that’s the case on a massive scale.
Completely. Waste is generated locally and therefore requires localized waste management solutions. Municipalities often fund these services, which are commonly known as municipal recycling programs, to support their local communities. No metropolis is similar. Denver, a thriving metropolis, boasts a state-of-the-art facility capable of processing 25 tons of recyclables per hour, making it a logical investment in sustainability. In Colorado’s Rocky Mountains, recycling is rare due to the lack of sufficient waste volume making it economically unviable.
Why are we concerned that recycling is absent in rural areas with sparse populations or insufficient waste volumes? To achieve a profitable outcome, you require a substantial amount of stock that justifies the investment. Is there a narrow gap, so you need to adjust? Wouldn’t it be beneficial to design a compact infrastructure capable of generating value without necessitating excessive volume? We’re also exploring that option.
What appears to be holding people back from achieving their goals are actually these artificially inflated prices.
The costs of utilizing a facility encompass capital equipment, sorting mechanisms, and conveyor systems. When you visit these facilities, you’ll navigate a complex network of conveyor belts that crisscross the area. The very thought of those conveyor belts sparks concern about their substantial financial burden. A facility capable of processing 25 tons per hour might incur construction costs ranging from $10 million to $20 million. Although seemingly insignificant within the mining industry, this phenomenon has significant implications elsewhere. Can justification for a $20 million investment in recycling be made with such slim profit margins? The initial costs include the investment in sortation tools and conveyor belts. There are also dynamic prices, such as sourcing materials at varying costs and paying for freight to transport goods both inwardly and outwardly.
With razor-thin profit margins, the impact of adjustments in materials costs or varying regional expenses for essential supplies is substantial.
It’s massively impactful. In 2018, China abruptly halted its acceptance of subpar plastics from the United States. The disposal of these plastics became problematic, as the lack of viable alternatives led to service providers having to incur costs to properly dispose of them in landfills? The imperative for creative problem-solving arose, prompting the quest for novel applications and approaches to effectively manage these resources.
What counts as low-grade plastic? Are single-use plastics really necessary, or are we just stuck in a cycle of convenience and waste?
Nice query. The most valuable materials to recycle are aluminum cans, cardboard, polyethylene terephthalate (PET) plastic water bottles, and high-density polyethylene (HDPE) milk containers. Notwithstanding the existence of less valuable supplies, certain types of HDPE and polypropylene still retain a degree of worth. While supplies such as polystyrene, commonly used in pink solo cups, are often challenging to recycle and lack significant value. As China ceased accepting low-grade plastics imports, the industry faced a pressing need to innovate in sorting methods and find alternative applications. New technologies such as pyrolysis and metanalysis are emerging to convert plastics into progressive methods.
Are these supplies primarily used as the foundation for training your machine learning models and algorithms?
In reality, a strong motivation exists to excel in identifying and categorizing the most valuable materials. Nonetheless, AI-powered robotics in recycling can effectively identify supplies often overlooked in the process, thereby promoting a more environmentally friendly approach. As a provider of innovative solutions, we cater to supply chain needs that defy conventional categorization and traditional sorting methods, requiring tailored approaches to ensure seamless processing.
As we’ve become proficient in identifying the core technologies driving recycling innovation, thanks to the emergence of robots that have allowed our company to inject value into existing processes since our inception. During the process of retrofitting a worthwhile system, it is crucial to respect and integrate the existing services seamlessly? Raw materials used in packaging include high-density polyethylene, PET bottles, cardboard, and aluminum, among many others.
Okay. As a direct outcome of the MRF’s promotional decisions, they are carefully curating products that align with the preferences of their native clients, prioritizing items they are eager to buy. The quality of some supplies may not justify their choice. Can users employ the software tool to identify and compare various electronic devices they’re contemplating acquiring?
Completely. Users simply need to configure the robotic system’s decisions with a few intuitive clicks. If mid-day adjustments dictate selecting a particular item from the conveyor belt, given an excess quantity in the shipment, a few tweaks enable efficient picking. In addition to this, when they perceive the system is allowing an excessive amount of valuable waste, such as PET bottles, to pass through unsorted, they will adjust their priorities accordingly? In a setting where traditional sorting systems operate efficiently but lack flexibility, these robots truly excel due to their remarkable adaptability.
By leveraging AI as the initial detection tool in our operations, we can seamlessly adapt to process different materials and rapidly retool our facilities to accommodate the changes.
That’s fairly highly effective. While considering a human-operated system, a limitation exists in the number of devices that individuals can process and comprehend. Moreover, constantly alternating between roles will likely cause chaos and hinder productivity. Automation has yielded significant benefits for our clients, including enhanced efficiency, reduced costs, and increased accuracy.
Certainly. Hand sorting, a quintessential representation of mundane, grime-encrusted, and detrimental labor. The dangers of rummaging through trash are twofold: there’s a risk of encountering hazardous waste like broken glass or sharp objects, as well as exposure to toxic substances that can be harmful if inhaled or ingested. Workers don protective equipment, rendering extended work periods impractical in this hazardous environment. Automating this process proves advantageous. Our robots not only substitute labor costs but also generate revenue. This investment yields a significant return within a span of just 18 months for projects of this nature. While humans may struggle to efficiently sort various types of data, AI operates without such constraints.
Fees and costs can vary, often hiding in plain sight. Maintaining a multitude of gadgets in mind can be challenging for an employee when trying to prioritize tasks. Typically, hand sorters experience a remarkably short tenure, with average employment lasting just three to six weeks. The potential turnover may inadvertently result in misplaced expenditure on recruitment, coaching, and other associated costs. In numerous scenarios, automation has consistently demonstrated its immense value.
Our primary market is the USA’s major sortation hub. We have successfully integrated over 300 items into our services and retrofit services, enabling clients to utilize them seamlessly. Most of these organizations are based in the United States. We maintain a modest presence in Canada, Japan, and the EU, albeit a relatively small one. So we’re worldwide. Similar challenges persist across multiple industries. The European Union imposes heightened regulatory scrutiny on options, subsequently leading to more stringent purity requirements for the products being processed.
And what’s that vary? Is it like 95%?
Once we manufacture bales of recyclable materials, large volumes of sorted plastic, and sell them to a plastics reclamation facility, the quality of those bales hinges on whether they meet the yields their buyers are targeting? If they failed to meet the yield target, the bale was considered hazardous. Until now, the exact composition of the bale remains unidentified. It’s challenging to determine the exact amount of purity, as estimates can be quite difficult to make accurately? For plastic bales, a commonly cited guideline is that they should consist of at least 85% recyclable material. Aluminum cans require a purity level of at least 97% for optimal performance and quality. In reality, recycling has historically revolved around providing optimal materials, meeting specifications for downstream uses, and relying on processors to adapt to the quality of outputs received. The European Union is strengthening its regulations on waste management by mandating the increased recycling of all plastic materials, including those of lower quality that are typically not recycled in the United States.
Are we exploring innovative methods to recycle an array of materials beyond just cans and bottles?
Precisely, sure. To maximize efficiency, you seek to streamline every component.
Before embarking on recycling initiatives, don’t you think it’s crucial to first identify and address the needs of your clients regarding supply management and sustainability? Have you had a chance to get everything in order for your team yet? Have existing clients committed to purchasing these materials in sufficient quantities?
While some of its links are internal to a specific company, others may extend beyond the organization, which raises questions about the target audience.
The client is typically the entity that purchases packaged materials processed and sold by a Materials Recovery Facility (MRF), not just buys them.
Completely. The client would greatly benefit from a transparent marketplace where various commodities are valued according to their quality. Currently, the market functions on a transaction-by-transaction basis. Customers in specific regions tend to prefer purchasing from trusted suppliers who consistently deliver premium products. In a well-organized market, additional participants are likely to enter the fray, identifying profitable opportunities and leveraging these without requiring personal connections or online networks.
Can you pinpoint a reliable approach to determining the output of each bundle?
It relies on the method. To determine the efficiency of processes such as aluminum can recycling, weigh the bale both before and after processing to calculate the mass yield accurately. While we typically boast impressive first-rate yield figures, these metrics often mask all operational nuances. With the integration of AI analytics, you gain profound insights into the effectiveness of specific units or pieces of equipment.
That’s intriguing. Without this innovative approach, locations would likely suffer from a significant lack of… One of the most significant hurdles in waste management appears to be the scarcity of access to reliable and accurate information.
Sure. This valuable information is truly priceless to us. We can adapt our AI technology to seamlessly accommodate evolving changes in the waste management landscape. As part of our comprehensive suite of innovative visionaries, we prioritize harnessing creative momentum to fuel operational excellence. This strategy yields significantly higher returns and affords the adaptability to reprocess a broader array of materials with ease.
If you had piloted a scaled-down version of this approach in a small town or city, it would likely mirror the real thing.
A fleet of sturdy containers, each one designed to transport precious goods across the globe, was stationed alongside a sleek and efficient conveyor belt. Objects are efficiently sorted using a state-of-the-art pneumatic-based optical sorting system. This portable setup would be ideal for brief events, such as music festivals. In rural areas, there may be a need for something intermediate between the current situation and a comprehensive recycling facility.
Without human intervention, aside from someone loading the waste into the system.
Sure. Somebody hundreds, removes, and configures.
Unbelievable. Let’s go have a look.
Definitely.
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Abate De Mey
Podcast Chief and Robotics Founder
