Everything You need to know before purchasing an Optical Sorter

In a modern industry optical sorting machines became an essential tool in many different industries, providing various companies with impressive and accurate product sorting capabilities. No matter if you are a member of the company involved in pharmaceuticals, food processing, or any other industry which requires a precise sorting process, you must pick the correct optical sorting machine.

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They are going to save a lot of time. To provide you with an example, in the food industry optical sorting machines are used to sort fruits and other products. These machines can easily detect if a piece of fruit is fresh or ripe. In this article we are going to provide you with the most important information about optical sorting machines, to show you why you should invest in them.

What is an optical sorter?

In general optical sorters are types of machines, that utilize reflected light to analyze various products. They are provided with designed optical filters that, are capable of narrowing the reflected light into target wavelengths which, are used to analyze the difference between acceptable products and the ones that should be discarded . It should be noted, that there are many different types of optical sorting machines:

• Color Sorters Color sorters sort items by their color. They compare the color of each object to a set standard. If an item doesn’t match, it is removed. These are common in the food industry to sort things like grains, coffee beans, and nuts.
• Shape Sorters Shape sorters look at the shape of each object. They remove items that have the wrong shape. These are used in food production to sort things like French fries, candies, or fruits and vegetables to make sure they are uniform.
• Size Sorters Size sorters check the size of objects. They use cameras and lasers to measure items and sort them by size. This is important for making sure products like fruits are the same size when packaged.
• NIR (Near-Infrared) Sorters
  NIR sorters use special light to tell what materials are made of. They are helpful for sorting items that look similar but are made of different materials. These are used in recycling to separate different types of plastic.
• X-ray Sorters
  X-ray sorters check the density of items. They can find objects hidden inside, like bones in meat or other foreign materials in packaged foods. This helps keep food safe.
• Multi-Sensor Sorters
  Multi-sensor sorters use a mix of different sensors like color cameras, infrared, and lasers. They give a very detailed analysis of each object. These are used in places where high accuracy is needed, like recycling facilities or quality control in factories.

Key factors to consider before buying an optical sorter

Optical sorters are a big investment for industries like farming, recycling and food processing. These machines can help make work faster and more precise. Before buying one, it’s important to think about several factors to make sure the sorter will work well for you. Here are the main things to consider:

• Type of Material and Sorting Needs Think about what kind of material you need to sort. Different machines are made to handle different materials like grains, plastic, or fresh produce. Do you need to sort by color, shape, size or defects? Choose a sorter that matches your material and sorting needs. This will help make sure the sorting is accurate and efficient.
• Sorting Technology and Sensors Optical sorters use different kinds of technology like cameras, lasers, or special sensors. The right technology depends on what you need. If you need to sort by color, a high-resolution camera might be best. For materials like plastic, you may need more advanced sensors like infrared. Make sure you understand what kind of technology the sorter uses and if it will meet your needs.
• Capacity and Speed How much material do you need to sort each hour? Make sure the sorter can handle the amount you need. Bigger machines can sort more, but they also cost more. Picking the right capacity will help you avoid slowdowns and keep everything running smoothly.
• Ease of Setup and Maintenance The sorter should fit easily into your current production line. Check if the setup process is simple. Also, think about maintenance. Machines that are easy to maintain and don’t need frequent adjustments will save you time. Look for a machine that comes with good technical support and easily available spare parts.
• Total Cost The cost of owning a sorter is more than just the price tag. Think about energy use, maintenance, software updates, and training costs. A sorter that costs less to run may be better for you in the long term, even if it costs more to buy.
• Software and Data Many optical sorters have smart software that provides data in real time. This can help make the sorting process better and more accurate. Make sure the software is easy to use and can give you useful reports. Some machines also offer remote monitoring or AI features, which can make sorting even easier.
• Supplier Reputation and Support The company that makes the sorter is important too. A good supplier will give you training, customer service, and help if something goes wrong. Read reviews or ask other users to find out if the supplier is trustworthy and helpful.

In conclusion, buying an optical sorter means thinking about your sorting needs, your working environment, and your budget. By keeping these key factors in mind, you can choose a machine that will help you work more efficiently, reduce waste, and support the success of your business.

Types of Optical Sorters and Their Applications

Besides the types of optical sorters which we provided at the beginning, optical sorters can be also divided by the method in which they carry materials to analyze them. It is crucial because these three types provided below, work best in specific industries:

• Belt Sorters Belt sorters use a conveyor belt to move materials under sensors. The sensors check the objects. Belt sorters are good for big jobs because they can handle a lot of items at once. The belt keeps the materials lined up and spread out, making sorting more accurate. Belt sorters are often used in food processing (like sorting fruits, vegetables, and nuts) and recycling. The smooth, even movement is great for sorting items that need careful checking to ensure quality.
• Chute Sorters (Free-Fall Sorters)
  Chute sorters use gravity to move materials down a chute. As they fall, sensors look at the items and sort them. This type works well for small or loose materials like grains or seeds. Chute sorters are also used in mining to sort minerals. They are fast and do not need extra moving parts, which makes them simple and cost-effective. They also help reduce damage to products.

Key Features to Look for in an Optical Sorter

Another aspect that should be taken into consideration before buying the optical sorter is its key features. The first one are types of sensors used in the machine. Hence it is crucial, to choose a machine that has advanced optical technology (for InGaAs sorter), that is capable of accurately sorting various materials. The second important aspect are algorithms. The algorithm should be accurate, fool-proof and most importantly, able to provide you with varying parameters that best fit into the sorting material that you want to sort.

These machines should allow you to customize sorting settings that best suit your requirements. Another important aspect is the user interface. It should be relatively easy to use the machine and to configure it. The last element about which people tend to forget is maintenance as well as, service support. You should check what type of maintenance and service support is provided by the manufacturer of the machine. The machine should have easy maintenance protocols and a high quality customer support service. After all regular maintenance will reduce the risk of breakdowns to minimum.

Cost Considerations

Another crucial aspect is cost considerations. After all, cost is one of the most important factors when you decide to buy something. You should not only analyze the initial investment but also the so-called long-term return on investment (ROI). Remember the increased efficiency, the machine can provide to your business, thus resulting in potential cost and manpower savings. You should take into consideration such factors as improved product quality and reduced labor costs. 

In general it is relatively hard to judge the price of an optical sorter. The price mostly depends on the model in which we are going to invest. The most basic ones we can buy for about 20 000 – 25 000 euro, while the most advanced models might cost more than few hundred thousand euro. Each additional component like camera etc. might also increase the final price of the product. 

At first glance it might be expensive but there is no denial that optical sensors are cost-effective. This technology was utilized in many industries so it is easy to provide the reader with an example. Envac utilized optical sorters and combined them with their automated waste collection system. Results? Reduction of transport and collection costs of garbage in various cities by 50% . Furthermore, optical sensors were also utilized in limestone quarry in Finland where this technology allowed to extract 220 000 tons of white limestone . When we add to this reduction in manpower and 100% accuracy, then it is easy to realize, that optical sensors are in fact, a great investment. 

Customization Options

We covered this field briefly before but let’s focus on it a bit more. The manufacturer should be able to provide us with solutions, which are based on the individual needs of a specific, business environment. The machine should also provide you with options to sort by color, shape, size, texture, and various other characteristics. 

Evaluating manufacturers and suppliers

After you have checked all important factors, there is still one more thing that should be taken into consideration before buying the optical sorter and that is evaluating the manufacturer and suppliers. The most important thing is to check if the company from which you want to buy your product is trustworthy. Keep in mind that defining a clear evaluation process might help you select a proper supplier and monitor their performance. You should also check what type of post-purchase support, warranty etc. is provided by the manufacturer of the optical sensor .

Installation and integration of the optical sorter

During the process of installation of the optical sorter there are a few factors that should be taken into consideration, these are:

• Location requirements – it is crucial to design a suitable location for the equipment. Such factors like floor load capacity, ceiling height, and proximity, to other machinery should be taken into consideration;
• Safety requirements –to install an optical sorting machine it is paramount to adhere to all safety protocols, as well as, environmental factors. Thanks to this you will be able to reduce potential risks to a minimum;
• Electrical and power requirements – it should not be a surprise, that optical sensors are rather complex systems that rely on electric power to work properly. Hence, before installation it is crucial to assess the electrical and power requirements to avoid operational issues;
• Synergy with existing production lines – this is also  an important aspect. You need to check how well the optical sensor is going to integrate with your existing production lines;

Future-Proofing Your Investment

Last but not least you should check how well the investment is going to integrate with the future development of the company. The machine itself should be scalable while the business grows. Furthermore, the technology and software used in the optical sensor should be provided with regular updates. You should also take into consideration the integration and connectivity options of the optical sorting machine, especially in the modern world of the Internet. These machines should have standardized communication protocols and customizable connectivity features. They should also be able to integrate data management systems, thanks to which it will be easier to track and analyze sorting results.

Conclusion

In general choosing, a proper optical sorting machine is an extremely crucial decision that might significantly impact the efficiency of all sorting operations in your company. By taking into consideration all aspects mentioned above (such as company needs, types of optical sorters, integration options, or customization flexibility), you will be able to make a perfect choice and purchase the machine, which is going to align perfectly with the needs of your company. Remember also to choose a manufacturer with good opinions, who will be able to provide you with a high-quality equipment, that will allow you to maximize profits. 

Meat processing facilities face several challenges in their daily operations. Ensuring food safety, maintaining high throughput, and adhering to regulatory standards can be daunting tasks. Processing different types of meat with unique handling and temperature requirements makes this even harder. 

Finding a conveyor system that meets all these demands while being cost-effective and easy to maintain is challenging. Fortunately, there are solutions designed to address these specific needs. Read on to learn more about choosing the right meat-processing conveyor.

CRITICAL CONVEYOR SELECTION FACTORS 

Conveyors are essential in maintaining food safety, sanitation, and product quality during the primary (butchery) and secondary (dicing/portioning) processing stages through packaging. 

Choosing a meat processing conveyor involves careful consideration of several different challenges, including:

Hygiene Standards and Sanitation Requirements

Maintaining impeccable hygiene and sanitation standards is crucial for ensuring food safety and operational efficiency in meat processing facilities. Here’s how compliant conveyor equipment plays a pivotal role:

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• Stringent Standards Compliance: Food-grade conveyors must meet rigorous hygiene standards set by organizations like the American Meat Institute (AMI) and the USDA.
• Regulatory Adherence: Facilities must comply with HACCP and FDA regulations to minimize contamination risks and uphold product quality.
• Minimizing Cross-Contamination: Conveyor systems designed with accessibility and ease of cleaning in mind help mitigate cross-contamination risks during processing.
• Operational Efficiency: Adhering to these regulations contributes to safer and more efficient operations, avoiding legal and financial repercussions that can harm a company’s reputation.

By prioritizing hygiene and sanitation in equipment selection, meat processing facilities can optimize efficiency, reduce costs, and ensure the highest standards of food safety.

Type of Meat and Application/Process

The type of meat plays a critical role in selecting the right conveyor system. For example, ground meat requires different handling than hot dogs or frozen chicken tenders. Raw meat must be kept at specific temperatures for safety reasons.

Product Integrity and Yield

It’s essential to maintain high throughput capacities while preserving product integrity. Conveyance systems must prioritize gentle handling and minimal product damage. And beyond regulatory requirements, food safety practices significantly influence product quality and yield and operational efficiency.

• Extended Product Life: Effective sanitation practices prevent bacterial growth, extending product shelf life and reducing waste in processing.
• Minimizing Waste: Conveyors can be equipped with return lines that send stray bits back to previous processes or fitted with catch pans and accessories designed to capture them.

Throughput Capacity: Capacity & Uptime

Meat moves quickly from farm to slaughter to processing—poultry moves even faster. Conveyors need to be durable and reliable to run consistently with little maintenance. This ensures total uptime in a fast-paced meat processing environment.

Full Solution vs. Individual Conveyor

It is important for meat processing facilities to choose between a complete conveyor system and individual conveyors. A complete system offers seamless integration and enhanced automation, improving overall efficiency. On the other hand, individual conveyors provide more customization options to meet specific processing requirements.

Look at the entire process. This includes conveying equipment and as much automation upstream and downstream as possible. Options or equipment can automate additional processes. Services to consider are:

• Engineering layout design
• Expert opinions and advice
• FAT/testing availability
• Installation
• Millwright services

Utilizing OEM connections can create complete process systems through a one-stop shop. This approach is typically reserved for engineering firms and dealer/distributors who manage entire projects.

Material and Design Considerations

Selecting the right materials and designs for a conveyor system is crucial in meat processing. Conveyors must be made from materials resistant to corrosion and bacteria growth to ensure easy cleaning and sanitation. These materials must also withstand cleaning chemicals used in the process.

Designs must allow easy access for maintenance and cleaning. This reduces downtime and increases overall efficiency. Easy-to-clean equipment maintains hygiene standards and ensures smooth conveyor system operation.

TYPES OF PFI MEAT PROCESSING CONVEYORS

PFI offers a range of conveyor systems designed specifically for meat processing applications. All of our conveyors meet exceptional sanitation standards and comply with industry regulations.

Belt Conveyors

Belt conveyors are popular in meat processing due to their versatility, long-distance conveying, and low initial cost. 

• Flat belt conveyors are simple, modular solutions that fit throughout meat processing lines. Tight transfers, seamless integrations, and various belt materials keep production running for raw, cased, and processed meats.
• Trough belt conveyors like our Troughveyor, are ideal for conveying bulk meat across long distances with no loss.
• Incline belt conveyors elevate meat to processing equipment like mixers, blenders, ovens, and more. The Eleveyor is available in horizontal, incline, and Z-shape configurations to fit each application.
• Vertical lift conveyors have traditionally been used for dough handling, but effectively elevate ground meat. The PURLift’s self-tracking positive drive belt and belt scrapers ensure consistent vertical flow and no product waste. 

Bulk Handling Equipment

Bulk handling on the raw and kitchen sides uses dumpers to move large volumes of meat efficiently. These dumpers provide smooth and safe transfers while maintaining productivity. Their flexible and easy-to-clean design meets high sanitation standards.

Dumpers and Screw Augers

Dumpers efficiently unload bulk product totes to quickly introduce product to the processing line. They handle products smoothly to minimize contamination. Screw augers precisely move bulk materials without spillage or loss, while maintaining product temperature and integrity.

Both equipment types improve workflow and uphold sanitation standards. Their design allows easy cleaning and flexibility, crucial for productivity and safety in processing environments.

Bucket Elevators

Bucket elevators are perfect for moving products to different heights. They are ideal for elevating products to tall processes (or equipment), including slicing/dicing/portioning/grinding and packaging. 

Vibratory Conveyors

Vibratory conveyors provide gentle product handling and are typically used in frozen and processed meat lines feeding into packaging lines. They ensure efficient and sanitary product transfer.

These conveyors maintain product integrity and reduce the risk of cross-contamination. They offer precise control over product flow, making them ideal for applications requiring careful handling and distribution.

INNOVATIVE MEAT PROCESSING CONVEYOR SOLUTIONS

Choosing a conveyor system that prioritizes safety, efficiency, and adherence to industry standards is essential. At PFI, we design custom conveyors that meet high sanitation standards and adhere to regulatory guidelines. 

Click below to discover how PFI can optimize your meat processing operation with innovative conveyor solutions.

If you want to learn more, please visit our website Sortation Equipment.