Intelligent Process Control Approach for Smart Waste Handling in Manufacturing Industries

Ka. Suriyaprabha, Jamuna Sri P., Madhavan K., Santhosh S. — Fri, 19 Jun 2026 00:00:00 +0000

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.

Journal of Control Systems and Converters

Intelligent Process Control Approach for Smart Waste Handling in Manufacturing Industries