Sensor Based Sorting Machines for Mining Market Size - By Technology, By Capacity, By Application, By Distribution Channel Growth Forecast, 2026 – 2035

Sensor Based Sorting Machines for Mining Market Size

The sensor-based sorting machines for mining market was estimated at USD 145 million in 2025. The market is expected to grow from USD 154.6 million in 2026 to USD 286.6 million in 2035, at a CAGR of 7.1% according to latest report published by Global Market Insights Inc.

As a result of the growing demand for base metals, precious metals and industrial minerals, the mining industry worldwide is expected to grow due to new development of infrastructure, urbanization, and energy transition where significantly larger quantities of copper, nickel, and other minerals will be needed. With increasing volumes of material being mined, mining operators are being forced to optimize their operations, which leads to increased waste. Therefore, sensor-based sorting provides miners with the opportunity to pre-concentrate ore prior to processing, which improves efficiency and reduces the environmental impact associated with mining.
 

In addition, due to the increasing activity of the mining industry, many companies will now be required to explore lower grade deposits and more remote areas, making traditional beneficiation processes increasingly complex and expensive. The technology of sensor-based sorting allows mining companies to process ore selectively, which reduces the amount of material that needs to be transported downstream to the mill for processing and thus reduces energy and water. As a result of this technology, mining companies can now significantly increase their overall recovery rates, which is why sensor-based sorting is becoming a critical component of modern-day mining.
 

A major advantage of sensor-based sorting is that it reduces the operational costs of a mine. Traditional processes, including crushing, grinding and flotation, are typically costly due to the high energy cost associated with processing minerals. With sensor-based sorting, many of the low-grade waste rocks can be removed in the early stages of processing, thus reducing the amount of material to be processed, thereby decreasing the energy cost and wear on processing equipment and chemicals used; thereby creating a significant reduction in the processing costs and an increase in profit potential for mines operating in low-margin situations.
 

Additionally, sensor-based sorting can be an effective means of reducing direct processing costs, reducing the amount of tailings that need to be disposed of and reducing the amount of water that has to be used during processing. This can result in a significant reduction in the costs of compliance and potential legal liability for mining operations in areas with high energy costs or stringent regulations on environmental concerns, making it very appealing for mining companies looking to adopt more sustainable and cost-effective methods of extracting minerals. 
 

Sensor Based Sorting Machines for Mining Market Trends

The mining sensor sorting equipment industry is seeing rapid changes as companies try to achieve more efficiency and sustainability, along with pursuing technological innovation. The major focus of the sensors sorting system is on improving ore recovery, lowering operational costs, and complying with increasingly strict environmental regulations. This sector is also supported by developments in technology and automation and is benefiting from the increasing need for key minerals used for the global energy transition.
 

• Employing AI will help improve how these machines perform using sensor-based sorting. With AI, these machines can characterize ore on a continual basis, develop adaptive algorithms for sorting and conduct predictive maintenance. Furthermore, AI will provide the ability to adjust sorting parameters based on information gathered through the sensors, which will allow for improved recovery of mineral ore. Lastly, utilizing IoT platforms will provide vital support for both remote monitoring and remote operation of sensor-based sorting machines in remote locations.
   
• Environmental sustainability is not optional, it is a requirement for all business operators today. Mining companies are subject to extensive regulatory controls related to the management of tailings and reclamation, use of water and air quality and emissions of carbon dioxide (CO2). The use of sensor-based sorting technology serves environmental sustainability accomplishments by enabling the reduction of waste rock early in production and the reduction of energy intensive steps in the beneficiation process as well as reprocessing of old tailings material using sensor-based sorting technology for increase recovery and lesser environmental impact. Furthermore, the ability to recover valuable minerals from previously disposed of materials is aligned with the principles of a circular economy.
   
• Global energy transition has created unprecedented demand for several minerals (Lithium, Cobalt, and Rare Earth Elements) needed for battery production and renewable energy technology development. The deposits of these minerals are some of the lowest grades or have complex geologic formations which significantly increases the cost and complexity of traditional methods used to efficiently beneficial these minerals. Sensor-based sorting machines can be used to improve the recovery from these deposits as well as from tailings.
   
• A growing number of mining companies are moving away from traditional centralized operations and toward smaller, more geographically dispersed locations and remote projects as more small-scale mining operations become available. Manufacturers are responding to the growing trend of smaller scale mines by producing modular mobile sorters that can be easily installed and used in conjunction with existing workflows, thereby allowing for faster installation times, lower capital costs vs. traditional large stationary sorting plants, and providing more options for flexibility and scalability when using these types of sorting units at exploration or temporary operational sites.
   

Sensor Based Sorting Machines for Mining Market Analysis

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Based on technology, the market is divided into laser sorters, X-ray transmission, color based, near infrared, LIBS technology and others. The laser sorters segment generated a revenue of USD 50.7 million in 2025.
 

• Laser sorters, a type of sorting machine using advanced sensor technology, analyze ore particles based on their surface characteristics through laser technology. Unlike optical sorting and X-ray sorting techniques, which only measure the density and/or color difference of the ore, laser sorters can detect the mineral characteristics of the ore, e.g. mineral texture, mineral reflective property and mineral elemental composition. The mineral characteristics are determined using laser-induced breakdown spectroscopy (LIBS) with high energy laser pulses that vaporize a portion of the material to create an aerosol from which a light spectrum is created and analyzed to determine the elemental composition and other properties of the ore.
   
• The main benefit of laser sorters is that they are very precise machines that differentiate between minerals by chemical makeup instead of physical characteristics alone. Therefore, they can separate out the valuable minerals from all other undesirable materials, also known as gangue, even within difficult ore bodies. Laser sorters can also sort a broad range of particle sizes and can be especially beneficial for processing ores when there are very small differences in either color or density between the valuable and worthless materials. By reducing the amount of waste sent to downstream processing plants, laser sorters will enable other commercial processes to operate more efficiently, thereby allowing for large cost savings through the lower amount of energy, water, and reagents consumed in this part of the mine.
   
• Laser sorting has been rapidly adopted across the Mining sector for targeting high-value or critical minerals like Lithium (Li), Rare Earths (REES), and Tungsten (W). Typically, these critical minerals are sourced from deposit types having complicated mineralogy that impede conventional sorting equipment from achieving high recoveries; however, developments to utilize laser sorting to recover residual value in tailings projects have become increasingly popular due to an effective ability to identify valuable residual minerals with extreme precision to generate additional revenue streams. The movement towards sustainable mining and increased operational effectiveness has put laser sorters in a strong position as essential technologies for increasing resource utilization while meeting environmental compliance standards of organizations.
   

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Based on capacity, the sensor-based sorting machines for mining market is segmented into low (less than 150 ton/hr.), mid (150-350 ton/hr.) and high (more than 350 ton/hr). The mid segment held about 45% of the market share in 2025.
 

• Typically, the central range of capacity of the sensor-based sorting machines is 150-350 tons per hour which positions them midway between the pilot plants/small modular units and the large-scale plant scale sorting systems. The machines are intended to achieve primary or secondary pre-concentration of the run of mine/crushed ore as well as maintain sufficient throughout to negatively impact the downstream processing circuit. The typical application for many of the mines is using the sensor sorter to remove barren waste material ahead of the grinding to reduce the mill load and reagent usage or to establish parallel lines to help smooth the feed variability between shifts.
   
• In essence, mid-size machines offer robust handling of materials, as well as multi-sensor systems with real-time controls. The systems have been optimally designed for classifying particles in the approximate size range from ~20 to ~120 mm, with limits depending on both the sensor type and composition of the ore. At this range, the acquisition of data and decision times should be possible at low levels to avoid misclassifying products as speeds of the belts are increased; thus, it is common for suppliers to use high-intensity lighting to provide fast detectors and edge processing to allow them to classify materials in milliseconds.
   
• Mid-capacity sorter units represent the best cost/impact ratio economically; these kinds of sorter units are large enough to remove between 20%–40% (on average) of feed waste, depending on the mineral type, have a lower capex compared with ultra-high throughout sorters, and are ideal for brownfield retrofits where they would be placed between crushing and milling operations, as well as for greenfield modular plants with phased expansions. There are many practical applications for mid-capacity sorter units. For example, they can be used to pre-concentrate base metal ores, separate critical minerals to improve the quality of battery-grade and concentrate product and provide an opportunity to reprocess tailings and low-grade stockpiles to recover what were previously uneconomically recoverable materials.
   

Based on distribution channel, the sensor-based sorting machines for mining market is segmented direct sales and indirect sales. The indirect sales segment held exceeded USD 87.1 million in 2025.
 

• The use of indirect distribution channels supports the growth of sensor-based sorting technology in mining by increasing the area of distribution. Many manufacturers may not be able to establish direct distributions to many parts of the world. Indirect distribution channels allow for partnership with a distributor or an agent in the local market to provide product placement and market penetration using established distribution networks. By using established distribution networks, manufacturers can enter new and emerging markets more effectively, get products to customers with reduced logistical issues, and provide customers with timely delivery and support.
   
• Indirect distribution channels also allow manufacturers to concentrate on core product development and innovation while outsourcing their market development and distribution responsibilities to regional partners. In addition, indirect distribution channels provide manufacturers with excellent opportunities to leverage the resources of their local distributors or agents to maximize their effectiveness in markets with diverse regulatory environments and infrastructure. As the mining industry continues to become more globalized, it is anticipated that the reliance on indirect distribution channels will continue to increase and create opportunities for manufacturers to gain a scalable and cost-effective advantage.
   

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U.S. dominated around 75.6% share of North America sensor-based sorting machines for mining market with generating around USD 109.6 million revenue in 2025.
 

• Sensor-based sorting is a very maturing industry across the world, and the U.S. has the advantage of having a large mining sector with an advanced mining infrastructure and emphasis on efficiency. Many mining companies in the U.S. were early adopters of x-ray transmission (XRT) technology, laser sorters, and AI sorting systems for the purpose of maximizing the amount of ore extracted from the mine while minimizing the effect on the environment.
   
• Additionally, the U.S. has been increasingly focused on sustainability and compliance with stringent environmental regulations, which has helped to accelerate the adoption of sensor-based sorting within the U.S. and in conjunction with critical mineral projects including lithium and rare earth minerals required for electric vehicle and renewable energy supply chains.
   
• The global sensor-based sorting machines market is dominated by North America because of its combination of technology innovation, extensive mining operations and significant investment in automation. North America has many OEM’s and a great number of companies that provide advanced sorting solutions for base metals, precious metals and critical minerals. As demand for materials for use in lithium batteries is increasing and legislation for green mining is being implemented in North America, there will be a growth in North America as a provider of digitalized and sustainable mining solutions. Mining companies in the North America region also place emphasis on reducing their costs and maximizing resource efficiency; therefore, sensor-based sorting solutions will be a key technology for ensuring continued long-term competitiveness.
   

Europe sensor-based sorting machines for mining market held 30.1% share in 2025 and is expected to grow at 6.9% CAGR during the forecast period.
 

• In Europe, there’s a growing demand for sensor-based sorting equipment in the mining sector, which is being fueled by Europe’s high commitment to sustainability, as well as strict environmental regulations. Mining organizations located within the European region face pressure to decrease their waste production, energy usage, and water consumption; therefore, they are attracted to using sensor-based sorting technologies to accomplish these objectives.
   
• The European Union and individual nations have developed and implemented extensive frameworks and support systems for green mining, and circular economy principles, encouraging the wide-scale adoption of modern sorting technologies in mining operations throughout Europe particularly in respect to countries such as Germany, Sweden, and Finland, where significant mining activity occurs. More recently, the European mining industry has begun to focus on critical mineral extraction to support renewable energy production and electric vehicles; therefore, the demand for efficient ore-sorting technologies continues to grow.
   
• High-tech European mining companies embrace advanced technologies and are willing to invest heavily in digitalization and automation. As a result, there is an increasing demand for sensor-based sorting equipment with AI, real-time analytics, and multi-sensor configurations to allow the mining industry to optimize resource recovery and adhere to environmental, social and governance (ESG) standards.
   
• In addition, because of strong partnerships between mining companies and technology companies, there is also an increase in innovation around the design of mobile and modular sorting equipment for use at smaller and remote mining locations. Also, there are currently government incentives in place that support sustainable mining practices, along with increasing pressures and the need for critical minerals to support the transition to clean energy, which should lead to continued growth in the European market for sustainable mining solutions.
   

The Asia Pacific held market share of around 20.1% in 2025 and is anticipated to grow with a CAGR of around 6.9% from 2026 to 2035.
 

• The APAC region has experienced rapid growth within the last decade due to industrialization, infrastructure development, and higher demand for base metals and critical minerals. Most of the mining activity is performed in countries such as China, India and Australia, which are creating great opportunities for new sorting technologies that will help improve operating efficiencies and decrease overall operational costs. Australia has been leading the charge by implementing x-ray transmission (XRT) and laser-based sorting methods primarily for iron ore, gold and lithium projects, whereas China is focusing on automation and digitalization to achieve its sustainable development goals.
   
• Government support for sustainable mining has been implemented through initiatives aimed at encouraging technological upgrades to enable the mining industry to take advantage of automation. Increased usage of electric vehicles and renewable energy in China and India has resulted in an increase in the demand for critical minerals, leading to the need for sensor-based sorting to improve recovery rates from low grade ores and has led to many new innovations in this area by companies located in Australia and China, who are leaders in this technology. Due to their size, large mining companies and original equipment manufacturers in these countries can penetrate the worldwide market and drive innovation with the creation of modular and mobile sorting units designed for remote locations, thereby enhancing productivity for mining firms that have operations throughout this vast geographical area.
   

Middle East and Africa sensor-based sorting machines for mining market is growing at a CAGR of 5.7% during the forecast period.
 

• Countries in the MEA region are expected to experience rapid growth in the use of sensor-based sorting machine technology as a direct result of their large mineral reserves and the growing need to modernize mining practices. There is already a notable amount of investment by South Africa, Botswana and Namibia to develop innovative technologies that enhance the extraction of ore from these countries and dramatically lower the waste associated with it, specifically in the diamond, gold, and base metal mining sectors. Sensor-based sorting has emerged as an economical option for many mines facing water shortages and the need for energy-efficient processing.
   
• Positive economic growth and increased infrastructure development within LATAM will continue to support the adoption of newer, improved elevator technology, specifically machine room-less elevators, which will have an impact on future design and material development for elevator rope systems.
   
• In addition, the growth of aftermarket products, such as replacement ropes and predictive maintenance systems, is helping to create a culture of increased safety and efficiency among building owners. In addition, the gradual alignment of regulations in LATAM with international standards will contribute to the continued growth of the elevator rope market in Latin America.
   

Sensor Based Sorting Machines for Mining Market Share

TOMRA Mining is leading with 14% market share. TOMRA Mining, STEINERT, Metso, MineSense Technologies, and NextOre collectively hold around 30%, indicating moderately fragmented market concentration. These prominent players are proactively involved in strategic endeavors, such as mergers & acquisitions, facility expansions & collaborations, to expand their product portfolios, extend their reach to a broad customer base, and strengthen their market position.
 

Tomra Mining is the world's leading provider of sensor-based sorting solutions for the minerals industry, providing advanced X-ray transmission (XRT), near infrared (NIR) and Laser sorting technologies offer COM XRT (2.0) & XRT 300/FR systems both of which allow fast, efficient sorting of large ore particles. Tomra increases the quality of mined materials; reduces downstream crushing, grinding and chemical use, as well as increases recovery and grade in metallic and industrial mineral operations. As part of the company's technology development, Tomra has launched the contain deep learning integration solution; this helps to detect inclusions in complex mineral deposits and thus enhances the operational efficiency, sustainability and economic performance of most metallic and industrial mineral operations.
 

Metso offers particle-level sorting solutions that are intended to optimize mine productivity by decreasing the amount of energy and water used, while increasing the recovery of valuable metals from various ore types. By integrating complementary technologies (optical, XRT and sensors), Metso's solutions allow for the real-time processing of bulk ore using an integrated online analytics service. By designing the Metso solution to be simple to maintain and integrating easily into an existing process, Metso solutions provide a means to cope with declining ore grades and environmental constraints, using adequate automation and global service support. 
 

Sensor Based Sorting Machines for Mining Market Companies

Major players operating in the sensor-based sorting machines for mining industry are:

• Binder+Co AG
• Bühler Group
• Comex
• Eriez Manufacturing
• FLSmidth
• HPY Sorting Technology
• Metso
• MineSense Technologies
• NextOre
• Pellenc ST
• REDWAVE
• Scantech
• Sesotec
• STEINERT
• TOMRA Systems
   

Comex offers multi-sensor sorting units that combine different sensors such as XRF, RGB, NIR, and others for the mining application to separate very distinct ore types (iron, copper, rare earths, etc.) and optimize the resource recovery process through maximum waste removal as well as reduction in operating expenses. These industrial grade systems can be ordered in sizes up to 3 meters wide and are designed with the ability to achieve up to 99% separation efficiency. AI-based sensor fusion and early waste removal are key traits of these systems.
 

Sesotec manufactures modular and self-learning driven sorting solutions with fully integrated multi-sensors including high-resolution optical, inductive and NIR technology primarily used for processing industrial products. The company provides advanced precision sorting systems designed specifically for recycling applications but has implemented adaptive solutions that allow the company to provide its customers with advanced sorting capabilities using real-time intelligent signal processing to sort at millisecond accuracy by means of compressed air or flaps.
 

Sensor Based Sorting Machines for Mining Market News

• In July 2025, Binder + Co AG launched its CLARITY AI Sensor based sorting machines using artificial intelligence technology to analyze the optical and alloy differences in scrap aluminum. The machine is also offered in an AI Only option and LIBS Variants and can process six lanes of material at the same time. With the use of sensor fusion and machine learning, the sorting machine delivers superior accuracy and speed when separating cast and forged aluminum grade materials.
   
• In July 2025, at the International Conference on Minerals and Materials held in Sydney Australia, TOMRA Systems ASA announced the release of its deep-learning AI solution CONTAIN. This solution, integrated with TOMRA's XRT sorting systems for mineralogical analysis, will allow for real-time analysis of complex ores, including the identification of inclusion-type ores like tungsten, nickel, and tin, as well as the ability to dynamically modify grade-recovery thresholds based on the real-time analysis of the ore being processed, thus improving separation accuracy of complex ores larger than 65mm diameter.
   
• In June 2025, HPY Sorting Technology exhibited its new Photon AI Sensor System for recovering copper using cutting-edge photon counting X-ray imaging technology. Utilizing the unparalleled ability to spatially separate chalcopyrite from pyrite and resulting in resolution capabilities of 50μm, the revolutionary photon sensor will accurately identify approximately 60% of copper ores throughout the world and allow for accurate and efficient ore sorting within the mining industry.
   
• In May 2025, Bühler Group released its SORTEX AI700 Optical Sorter in London, which implements advanced deep-learning technologies based on convolutional neural networks (CNNs) that dramatically increases the ability to detect contaminants in processed foods and grain products. This high-performance precision sorter was developed specifically to accurately and efficiently sort Gluten-Free Oats and other specialty products.
   
• In April 2025, GiGi Investments will launch the Circle Series X-ray transmission (XRT) sensor-based sorting machine of HPY Sorting Technology in Southern Africa. The XRT method provides an advanced solution for precise ore sorting and assists with efficiency in mining operations and enhanced recovery of resources in the region.
   

The sensor-based sorting machines for mining market research report includes in-depth coverage of the industry with estimates & forecasts in terms of revenue (USD Million) & volume (Thousand Units) from 2022 to 2035, for the following segments:

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Market, By Technology

• Laser sorters
• X-Ray transmission
• Color based
• Near infrared
• LIBS technology
• Others (XRF, Eddy Current)

Market, By Capacity

• Low (less than 150 tons/hr.)
• Mid (150-350 tons/hr.)
• High (more than 350 tons/hr.)

Market, By Application

• Metallic
• Nonmetallic

Market, By Distribution Channel

• Direct sales
• Indirect sales

The above information is provided for the following regions and countries:

• North America
  • U.S.
  • Canada
• Europe
  • Germany
  • UK
  • France
  • Italy
  • Spain
• Asia Pacific
  • China
  • India
  • Japan
  • Australia
  • South Korea
• Latin America
  • Brazil
  • Mexico
  • Argentina
• Middle East and Africa
  • South Africa
  • Saudi Arabia
  • UAE