Intelligent Process Control Approach for Smart Waste Handling in Manufacturing Industries
Keywords:
Arduino Uno, GSM alert system, Industrial automation, IoT, Process control, Sensor-based classification, Smart waste management, Waste segregationAbstract
The rapid industrialization and growing waste generation in manufacturing environments have presented substantial challenges in waste management and environmental sustainability. Conventional waste management systems depend primarily on manual segregation, which is susceptible to contamination, low recycling rates, health hazards for workers and increased operational costs. To tackle these issues, this paper proposes a process control approach for smart waste handling in manufacturing units with an automated waste segregation smart dustbin system. The proposed system is an intelligent decision-making and automated segregation system that integrates multiple sensors like moisture sensors, infrared sensors, ultrasonic sensors and inductive proximity sensors with an Arduino Uno microcontroller. Waste materials are analyzed based on physical characteristics in real time, and a servo motor mechanism directs the waste into appropriate biodegradable or non-biodegradable compartments. Further, the ultrasonic sensors monitor the fill levels of bins continuously. Also, a GSM module is used to send remote alerts for proper waste collection and maintenance. The system also comprises efficient power management techniques and is designed to support future integration with the IoT and solar energy systems. The experimental analysis shows a global accuracy for segregation of about 92.7% with a robust real-time performance. The proposed smart waste handling framework enhances operational efficiency, reduces manual intervention, improves worker safety and enables sustainable waste management practices in modern manufacturing environments.
References
A. Lakhouit, “Revolutionizing urban solid waste management with AI and IoT: A review of smart solutions for waste collection, sorting, and recycling,” Results in Engineering, vol. 25, Mar. 2025.
S. V., S. P., and H. J. R. Selvaraj, “Smart waste segregation and monitoring system using IoT,” International Research Journal of Multidisciplinary Technovation, vol. 1, no. 2, pp. 1–10, 2019.
A. U. Gondal, M. I. Sadiq, T. Ali, M. Irfan, A. Shaf, M. Aamir, M. Shoaib et al., “Real time multipurpose smart waste classification model for efficient recycling in smart cities using multilayer convolutional neural network and perceptron,” Sensors, vol. 21, no. 14, 2021.
T. Faisal, M. Awawdeh, and A. Bashir, “Design and development of intelligent waste bin system with advertisement solution,” Bulletin of Electrical Engineering and Informatics, vol. 10, no. 2, pp. 940–949, 2020.
J. P, N. M., R. N., and B. P., “Arduino-based automated waste segregation system for efficient recycling,” Journal of Electrical Engineering and Automation, vol. 8, no. 1, pp. 25–39, Mar. 2026.
A. M. Alfaidz, H. Z. Avansyah and M. Rosmiati, “Revolutionizing waste management with an IoT smart bin featuring app and sensor fusion for waste segregation,” 2025 IEEE International Conference on Networking, Intelligent Systems, and IoT (ICONS-IoT), Bandung, Indonesia, pp. 135–141, 2025.
M. K. Hasan, M. A. Khan, G. F. Issa, A. Atta, A. S. Akram and M. Hassan, “Smart waste management and classification system for smart cities using deep learning,” 2022 International Conference on Business Analytics for Technology and Security (ICBATS), Dubai, United Arab Emirates, pp. 1–7, 2022.
S. M. Maturi, S. R. Dhanikonda and S. Giddaluru, “Smart dustbins: Real-time monitoring and optimization for waste management in smart cities through IoT devices,” Engineering, Technology and Applied Science Research, vol. 15, no. 1, pp. 19246–19252, Feb. 2025.
Abhishek, I. Verma, I. Arya, L. Sen, “A review of smart waste management systems using IOT and embedded technologies,” International Journal of Engineering Research & Technology, vol. 13, no. 06, 2025.
N. Mohd Yusof, M. Faizal Zulkifli, N. Yusma Amira Mohd Yusof, and A. Afifie Azman, “Smart waste bin with real-time monitoring system,” International Journal of Engineering & Technology, vol. 7, no. 2.29, pp. 725–729, May 2018.
A. G. Sharma, G. S. Chandu, and N. S. Rao, “Energy efficient waste management system using Internet of Things,” in Nanoelectronics, Circuits and Communication Systems, Lecture Notes in Electrical Engineering, pp. 7–13, 2020.
M. K Chigateri, R., S., K. C H, S. Kumar, “Automatic waste segregation using embedded system,” International Journal of Advanced Research in Science, Communication and Technology, vol. 6, no. 1, Jan. 2026.
A. Ayyanagoudar, A. Mohankar, J. Gharte, P. Pasnsare, B. Ainapure and B. Appasani, “A smart bin with real-time monitoring and garbage level tracking using IoT,” 11th International Conference on Reliability, Infocom Technologies and Optimization (Trends and Future Directions) (ICRITO), Noida, India, pp. 1–7, 2024.
M. X. Soh, H. K. Mun, H. Z. Lee, Z. K. Ng, and Y. C. Hum, “AI- and IoT-enabled smart dustbin for automated hazardous electronic waste separation,” Engineering Proceedings, vol. 134, no. 1, Mar. 2026.
F. Fotovvatikhah, I. Ahmedy, R. M. Noor and M. U. Munir, “A systematic review of AI-based techniques for automated waste classification,” Sensors, vol. 25, no. 10, May 2025.
