Optical sorting (sometimes called digital sorting) is the automated process of sorting solid products using cameras and/or lasers. Depending on the types of sensors used and the software-driven intelligence of the image processing system, optical sorters can recognize an object's color, size, shape, structural properties and chemical composition. The sorter compares objects to user-defined accept/reject criteria to identify and remove defective products and foreign material (FM) from the production line, or to separate product of different grades or types of materials. Optical sorters are in widespread use in the food industry worldwide, with the highest adoption in processing harvested foods such as potatoes, fruits, vegetables and nuts where it achieves non-destructive, 100 percent inspection in-line at full production volumes. The technology is also used in pharmaceutical manufacturing and nutraceutical manufacturing, tobacco processing, waste recycling and other industries. Compared to manual sorting, which is subjective and inconsistent, optical sorting helps improve product quality, maximize throughput and increase yields while reducing labor costs.
History Optical sorting is an idea that first came out of the desire to automate industrial sorting of agricultural goods like fruits and vegetables. Before automated optical sorting technology was conceived in the 1930s, companies like Unitec were producing wooden machinery to assist in the mechanical sorting of fruit processing. In 1931, a company known as “the Electric Sorting Company” was incorporated and began the creation of the world’s first color sorters, which were being installed and used in Michigan’s bean industry by 1932. In 1937, optical sorting technology had advanced to allow for systems based on a two-color principle of selection. The next few decades saw the installation of new and improved sorting mechanisms, like gravity feed systems and the implementation of optical sorting in more agricultural industries. In the late 1960s, optical sorting began to be implemented to new industries beyond agriculture, like the sorting of ferrous and non-ferrous metals. By the 1990s, optical sorting was being used heavily in the sorting of solid wastes. With the large technological revolution happening in the late 1990s and early 2000s, optical sorters were being made more efficient via the implementation of new optical sensors, like CCD, UV, and IR cameras. Today, optical sorting is used in a wide variety of industries and, as such, is implemented with a varying selection of mechanisms to assist in that specific sorter’s task.
The sorting system
In general, optical sorters feature four major components: the feed system, the optical system, image processing software, and the separation system. The objective of the feed system is to spread products into a uniform monolayer so products are presented to the optical system evenly, without clumps, at a constant velocity. The optical system includes lights and sensors housed above and/or below the flow of the objects being inspected. The image processing system compares objects to user-defined accept/reject thresholds to classify objects and actuate the separation system. The separation system — usually compressed air for small products and mechanical devices for larger products, like whole potatoes — pinpoints objects while in-air and deflects the objects to remove into a reject chute while the good product continues along its normal trajectory. The ideal sorter to use depends on the application. Therefore, the product's characteristics and the user's objectives determine the ideal sensors, software-driven capabilities and mechanical platform.
Sensors Optical sorters require a combination of lights and sensors to illuminate and capture images of the objects so the images can be processed. The processed images will determine if the material should be accepted or rejected. There are camera sorters, laser sorters and sorters that feature a combination of the two on one platform. Lights, cameras, lasers and laser sensors can be designed to function within visible light wavelengths as well as the infrared (IR) and ultraviolet (UV) spectrums. The optimal wavelengths for each application maximize the contrast between the objects to be separated. Cameras and laser sensors can differ in spatial resolution, with higher resolutions enabling the sorter to detect and remove smaller defects.
Cameras
Monochromatic cameras detect shades of gray from black to white and can be effective when sorting products with high-contrast defects. Sophisticated color cameras with high color resolution are capable of detecting millions of colors to better distinguish more subtle color defects. Trichromatic color cameras (also called three-channel cameras) divide light into three bands, which can include red, green and/or blue within the visible spectrum as well as IR and UV. The interaction of different materials with parts of the electromagnetic spectrum make these contrasts more evident than how they appear to the naked human eye. Coupled with intelligent software, sorters that feature cameras are capable of recognizing each object's color, size and shape; as well as the color, size, shape and location of a defect on a product. Some intelligent sorters even allow the user to define a defective product based on the total defective surface area of any given object.
Lasers While cameras capture product information based primarily on material reflectance, lasers and their sensors are able to distinguish a material's structural properties along with their color. This structural property inspection allows lasers to detect a wide range of organic and inorganic foreign material such as insects, glass, metal, sticks, rocks and plastic; even if they are the same color as the good product. Lasers can be designed to operate within specific wavelengths of light; whether on the visible spectrum or beyond. For example, lasers can detect chlorophyll by stimulating fluorescence using specific wavelengths; which is a process that is very effective for removing foreign material from green vegetables.
Camera/laser combinations Sorters equipped with cameras and lasers on one platform are generally capable of identifying the widest variety of attributes. Cameras are often better at recognizing color, size and shape while laser sensors identify differences in structural properties to maximize foreign material detection and removal.
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