A ballistic separator does in one machine what would otherwise take two or three. It splits waste simultaneously by shape, density and size, producing three separate streams: flat material, rolling material and the fine fraction. In industry terms, the 2D fraction, the 3D fraction and the fines.
The principle is mechanical and straightforward. An inclined ramp is built from perforated paddles, fixed to two crankshafts, one at the top and one at the bottom. As the shafts turn, the paddles describe an oscillating, ballistic motion that throws the material up and forward. Flat, light items are driven upward to the top end. Rigid, round items roll down the slope of the ramp. Small material falls through the perforations in the paddles. See the full range of waste sorting equipment and how the machines connect.
Key Advantages of a 2D/3D Ballistic Separator
• Three fractions in one pass, a ballistic separator replaces two or three separate machines, because it separates by shape, density and size at the same time.
• It prepares optical sorting, optical sorters and robots work far more accurately on a flow already split into flat and rolling than on mixed waste, so the downstream investment pays back.
• Adjustable angle, 10 to 25 degrees, the ramp inclination is set to match the waste composition, so separation quality is tuned without changing equipment.
• It pulls film out of the rigids, separating 2D from 3D is the most effective mechanical way to clean a rigid container fraction of film and paper.
• No screen to blind, the perforations sit in paddles that are constantly moving, so there is no fixed surface to clog as on a classic screen.
• Low energy consumption, for the duty it performs, a ballistic separator has a modest installed power, between 5.5 and 11 kW.
Technical Specifications, Ballistic Separator
| Parameter | 4 paddles | 6 paddles | 8 paddles | 10 paddles |
|---|---|---|---|---|
| Number of paddles | 4 | 6 | 8 | 10 |
| Working area (m²) | 8 | 12 | 16 | 20 |
| Indicative throughput (t/h) | 5–10 | 10–15 | 15–20 | 20–25 |
| Installed power (kW) | 5.5 | 7.5 | 11 | 11–15 |
| Indicative weight (t) | 6 | 9 | 12 | 15 |
| Angle adjustment (°) | 10–25 | 10–25 | 10–25 | 10–25 |
| Output fractions | 3 (2D, 3D, fines) | 3 (2D, 3D, fines) | 3 (2D, 3D, fines) | 3 (2D, 3D, fines) |
The figures for the 4 to 8 paddle configurations correspond to published manufacturer ranges. The 10 paddle configuration and its throughput are extrapolated and confirmed at quotation. Real throughput depends on waste composition and inlet particle size.
Applications for 2D/3D Separation
• Municipal waste sorting plants, separating recyclables from mixed waste, as the stage preceding optical sorting.
• Plastic recycling, separating film from rigid containers, two fractions with entirely different prices and destinations.
• Paper and cardboard, extracting the flat fraction from commingled recyclables.
• Construction and demolition waste, separating wood and flat material from the heavy rolling fraction.
• Composting, removing contaminants from organic waste, especially plastic film.
• Alternative fuel production, concentrating the light, high calorific fraction.
How It Works
The access ramp of the machine is built from longitudinal perforated paddles. Each paddle is fixed at both ends to a crankshaft, one mounted transversally at the top, the other at the bottom. As the shafts rotate, each paddle describes an elliptical motion, and neighbouring paddles move out of phase. The result is a throwing trajectory, which is where the name ballistic comes from. The material receives both an upward and a forward component of motion. Flat, light objects, paper, cardboard, film, have a large surface and low weight, so they are carried up the ramp and exit at the top as the 2D fraction. Rigid, compact objects, bottles, cans, containers, crumpled textiles, do not rest on the surface, roll down the slope and exit at the bottom as the 3D fraction. Small material passes through the paddle perforations and is collected underneath as the fine fraction. The three streams go to different destinations.
Selection Guide
The number of paddles determines the working area and therefore the throughput. As a guide, 4 paddles for 5 to 10 tonnes per hour, 6 paddles for 10 to 15, 8 paddles for 15 to 20. The second parameter, just as important, is the inclination angle. A steeper angle pushes more material into the 3D fraction, a shallower one favours the 2D fraction. Because the angle is adjustable between 10 and 25 degrees, the same machine can be optimised over time, once you see what your waste actually contains. A ballistic separator gives its best results on material that has already been through a screening stage, so it is usually placed after the trommel or the star screen.
Frequently Asked Questions
What exactly are the 2D and 3D fractions?
The 2D fraction is flat, light material: paper, cardboard, plastic film, that is objects with a large surface and low weight. The 3D fraction is rigid, three-dimensional material that rolls: bottles, aluminium cans, plastic containers, crumpled textiles. Separating them mechanically is valuable because the two fractions have different buyers and different prices.
Why do I need a ballistic separator if I already have a trommel screen?
They are completely different separation criteria. A trommel screen separates by size, so a large sheet of film and a large bottle leave together. A ballistic separator separates by shape and density, so it splits them apart. The two machines complement each other rather than replace each other, and in well designed plants they are used one after the other.
How does the angle affect the separation result?
Directly and strongly. At a steeper angle more material rolls down, so the 3D fraction grows but may also contain flat items. At a shallower angle upward transport is favoured, so the 2D fraction grows but may carry light rigids with it. The adjustment between 10 and 25 degrees is made on the real material, during the first weeks of operation.
Do the paddle perforations clog?
Significantly less than a fixed screen, because the paddles are in constant motion and the vibration and phase difference between them shake off stuck material. On very wet waste a screening stage beforehand is still recommended, to remove most of the fine and wet fraction.
Is the equipment supplied new?
Yes. We supply new units only, made to order for your application, with complete technical documentation.
What maintenance does a ballistic separator need?
Checking the crankshaft bearings, which are the most heavily loaded parts, inspecting the paddles for wear and deformation, checking the belts or the transmission and cleaning the perforations. Being a machine with few components and low installed power, its maintenance is among the simplest in the whole line.
Why URSTAG?
URSTAG is a premium brand of recycling equipment, with over 15 years of experience. You don't just get a machine, you get a solution engineered by specialists, built from top-tier components and backed by a team that supports you from design through commissioning.
• European engineering, every machine and every complete line is designed by our engineering teams in Europe, with a focus on reliability, safety and energy efficiency.
• Premium components, we build on motors and automation from industry leaders: Siemens, Schneider Electric, ABB, WEG, SEW-Eurodrive, NORD Drivesystems and Bonfiglioli.
• Over 15 years of experience, we know how materials and machines behave in real-world operation, and we configure each solution for your flow and volume.
• New equipment, configured for you, we supply new units, made to order for your application, with complete technical documentation.
• Delivery, installation and training included, we handle transport, commissioning and operator training, with support throughout the equipment's life.
As a premium brand, URSTAG relies on European engineering, top-tier components and experience. You choose a partner that supports your production long term, with equipment built to run reliably in demanding industrial environments.
