Recycling sort systems made in the USA

Our sort system manufacturing process

Fluent Conveyors designs, engineers, and manufactures every conveyor system to rigorous tolerances. Our sort systems are built to withstand demanding recycling and waste management applications with minimum maintenance.

1. Design: our engineering team uses advanced 3D CAD software to design sort systems to match project specifications. We offer standard 3, 4, 6, 8, 10, and 12-person sort lines in lengths from 10 to 30 feet. Inclines range from 25–35 degrees.
2. Manufacturing: we produce robust structural steel frames using 3/16-inch rectangular tubing, 1/4-inch steel pan side walls, and 1/4-inch steel supports. 25–30 lb rail tracks provide sturdy chain support. Precision tools such as CNC machining and automated braking allow extremely tight tolerances.
3. Components: our conveyors feature industrial strength components such as hinged steel belts, durable rubber belts, flame-treated sprockets, direct drives, cold-rolled shafts, and heavy-duty bearings. We also integrate walkways, stairs, railings, and other customizable accessories per your request.
4. Testing: before shipment, every sort system is fully assembled, inspected, and undergoes over 10 hours of performance checks. We validate speed, tracking, alignment, noise levels, safety stops, and electrical so your system arrives ready for seamless integration.

Rugged structural integrity combined with premium conveyor components allows our sort systems to deliver maximum uptime. 

Engineered and built to CEMA standards

At Fluent Conveyors, we are dedicated to following the most rigorous industry standards for conveyor safety, installation, and operation. All of our conveyors and sort stations are designed, engineered, and manufactured to align with standards put forth by CEMA, the Conveyor Equipment Manufacturers Association. This includes adherence to CEMA standards for the following:

• Conveyor alignment tolerances
• Conveyor belt training methods
• Safety label placement
• Maintenance procedures
• Equipment specifications
• Balanced belt tensioning
• Electrical safety requirements
• Conveyor run-in procedures
• Chain and sprocket specifications
• Noise reduction methods
• Conveyor inclines and curving
• Installation practices
• Belt ratings and capacities
• Startup procedures
• Bearing selection and load ratings
• Lubrication methods
• Guarding principles
• Lockout/tagout protocols
• Troubleshooting techniques
• Mechanical engineering expertise
• Structural fabrication methods
• Precision alignment best practices
• Belt scraping and sealing
• Idler adjustment guidance
• Reducer/motor base installation
• Flexible coupling alignment

We hold our team and processes accountable to CEMA's standards so our customers receive conveyor systems that meet strict quality guidelines for safety, performance, and reliability. Our commitment to following CEMA standards is a key part of our vision to deliver state-of-the-art material handling solutions.

Fluent sort systems at a glance 

Fluent Conveyors manufactures high-quality custom sort conveyors engineered specifically for recycling applications, but there’s more to it than that.

• Top-of-the-line conveyors: heavy-duty, customizable conveyors for large volume, abrasive, and high-temperature recycling materials, integrating smoothly with other recycling equipment.
• Replacement parts: essential replacement parts such as roller chains, sprockets, and belts to quickly resume operations in case of system failures.
• Maintenance: includes lubrication, tension checks, and alignments. Fluent Conveyors offers manuals, dealer support, and troubleshooting guides for easy upkeep.
• Safety equipment: equipped with OSHA-compliant safety features such as walkways and emergency stops.

Does Fluent offer custom recycling sort systems?

Fluent Conveyors offers pre-engineered standard recycling sort stations for common configurations such as 3, 4, 6, 8, 10, and 12-person sort lines. We also design custom conveyors tailored to your operation.

Our customized sort systems are tailored to your material streams, facility limitations, equipment integrations, and output goals. Our roller chain conveyors and sort stations form the framework for customizable multi-stage systems.

What are the components of a Fluent sort system?

A fully functional sort system works seamlessly to segregate material streams. Modular designs allow us to customize an innovative solution for your operation.

Infeed and extraction conveyors

Our roller chain conveyors, slider bed conveyors, flat idler conveyors, and trough idler conveyors move raw materials into the system and transport separated materials to downstream equipment. 

Walkways, stairs, and rails

Walkways, stairs, and rails provide sorting staff safe access across conveyor lengths. Stair towers and safety handrails for OSHA compliance. 

Fluent equips transverse walkways with railings spanning conveyors at optimal sorting heights.

Transition hoppers and chutes

Hoppers and chutes act as material buffers or reservoirs between conveyor stages and aid in redirecting material flow to prevent spillages and blockages. Our hoppers handle high volumes.

Adjustable platforms

Platforms bolt onto conveyor frames to allow height adjustments as per ergonomic sorting needs. Custom-fabricated platforms span multiple sorters. Suspended belly pans provide comfort and security.

Sorting chutes and cabins

Guides separated material streams by grade into appropriate containment for baling or temporary storage. Our chutes are abrasion-resistant, while cabins keep manual sorting isolated.

Electricals and drives

Motorized drives tune belt pace for optimal manual sorting velocity. Control panels house VFDs and PLCs that integrate sensor cues to synchronize the system. 

We size premium motors and lubricated gearboxes based on loads.

What sorting technologies do Fluent sort stations incorporate?

Fluent Conveyors can engineer custom systems with advanced sensors, screens, magnets, optical sorters, and other components to simplify the recycling process.

• Optical sorter: uses cameras, lasers, and NIR sensors to identify and separate materials based on optical properties, enabling paper, plastic, and metal differentiation.
• Magnetic separator: extracts ferrous metals from the stream using magnetic drums or pulleys.
• Eddy current separators: induces a magnetic field to repel and separate non-ferrous metal.
• Manual sorting cabin: stationed along a conveyor line for manual sorting of irregular or mixed materials through chutes.
• Air sorter: separates paper, plastic, and metals through airflow based on weight and density differences.
• Screening system: classifies material by size using trommels, disc screens, and drum separators.
• Balers and briquetters: densify and compact sorted material streams for efficient transport and storage.

Which industries do Fluent’s sort systems serve?

Our recycled material handling systems improve the sorting process within the following industries:

• Material recovery facilities: separate organic waste from plastic waste, glass waste, metals, and other recyclables. 
• Construction & demolition (C&D): durable enough for soils, aggregates, wood, drywall and metals. Withstands impacts from debris and protruding rebar.
• Plastics processing industry(PET, HDPE, PVC): improve plastic recycling rates.
• Glass recycling industry: improve sorting rates for glass bottles.
• E-waste: abrasion-resistant frames and guided chutes handle electronics and appliances with sharps and glass.
• Old corrugated cardboard (OCC): withstands moist paper and the fibrous fines burdening chain drives. Compatible MOC for paper recycling.
• Single-stream recycling: utilize glass, cardboard, paper, aluminum, and plastic separators to 
• Dual-stream recycling: optimized to concurrently handle multiple independent material flows (cans, paper, plastic, etc.) throughout the facility.

See a full list of industries we serve.

How can I maintain my sort system?

We make our conveyors and sort stations easy to maintain. We’ll provide you with complete instructions for chain lubrication, belt alignment, pulley cleaning, and replacing bearings, sprockets, and other components.

Fluent Conveyors supplies all standard parts such as motors, bearings, sprockets, and drum pulleys for quick replacements in case any component fails unexpectedly.

We also provide detailed equipment manuals with preventative protocols to sustain optimal conveyor performance. 

We offer parts support and field technicians for major repairs so you can maintain a consistently high throughput rate for your operation.