Case Study
Plaswire: AI-Verified Traceability for Plastic Recycling
MateriAI deployed at Plaswire — tracking every gram of material from intake to dispatch, with QR-coded bags, live IoT sensors, and EU Digital Product Passports built in.
Client
Plaswire
Sector
Recycling
Location
Northern Ireland
Product
MateriAI
Overview
Plaswire is our first recycling customer and the live deployment site for MateriAI — the manufacturing execution system we built for plastics recyclers and the circular economy. Every stage of the process, from waste arriving at the gate to finished product leaving the dock, is tracked, weighed, and digitally passported.
Challenge
Most plastics recyclers are stuck between clipboards and hundred-thousand-pound enterprise MES. Neither works. Meanwhile the EU Digital Product Passport becomes mandatory in 2027, energy costs keep climbing, and buyers increasingly demand verified recycled content on every invoice. Plaswire needed a system that could track every bag through every stage, read energy from every machine, and generate compliant paperwork without a twelve-month rollout.
Solution
MateriAI: a cloud platform, tablet operator app, and LoRaWAN IoT sensor network, deployed live across the Plaswire site.
Material Tracking & QR Genealogy
Every bag QR-coded. Every material traced through intake, shredding, granulation, blending, and dispatch — with full genealogy from source waste to finished product.
IoT Sensors & Per-Machine Energy
LoRaWAN sensors read electricity, temperature, and throughput on every critical machine. Tariff-aware cost data flows straight into operator dashboards and CO₂ reports.
EU Digital Product Passport — out of the box
Native JSON-LD generation for EU DPP compliance, GS1 EPCIS 2.0 event capture, and ISO 14040 life-cycle assessment — all produced from the data already being captured on the shop floor.
Results
- Paper clipboards replaced by a tablet-first operator app across the shop floor
- Every bag, batch, and blend queryable with full upstream genealogy
- Live per-machine energy and CO₂ data feeding operator and board-level reports
- EU Digital Product Passport generation ready ahead of the 2027 mandate
What MateriAI delivers
- Material & batch tracking
- QR-coded bag genealogy
- Blend recipe management
- Per-machine energy monitoring
- EU DPP & LCA reporting
- Tablet-first operator app
Technology stack
- AWS serverless back-end
- LoRaWAN sensor network
- GS1 EPCIS 2.0 event capture
- ISO 14040 LCA
- Next.js operator dashboards
