Implementation of the Optical Sorting System

As the technical director of a breakfast cereal manufacturer, I was faced with a critical problem: contamination with foreign bodies in oat batches. The manual process was slow and inefficient, and the risk of shipping non-compliant products was unacceptable.

After a thorough market analysis, we chose to collaborate with Pilavtime for the implementation of a complete optical sorting line. The project was structured in three major phases, and their team demonstrated remarkable transparency from the very beginning.

Technical Details and Performance

The installed system uses high-resolution CMOS sensor cameras and specialized LED lighting to detect differences in color, texture, and shape. The image processing software, configured for oats, can automatically identify and reject fragments of stones, green grains, or other foreign materials.

• Processing Capacity: Up to 2.5 tons/hour.
• Sorting Accuracy: 99.8% under standardized testing conditions.
• Integration: Seamlessly interfaced with our existing conveyor and packaging system.
• Maintenance: Preventive service intervals at 500 operating hours.

After six months of continuous operation, our internal data shows a 97% reduction in complaints related to impurities. The line's yield increased by 22% due to the superior speed and elimination of stops for manual inspection.

Impact on Quality Standards

The greatest added value was in the quality assurance department. The system generates automatic reports for each batch, with images of rejected impurities and timestamps. These are essential for our internal audits and for those of partners requiring compliance with strict standards (IFS, BRC).

The technical expertise of the Pilavtime team was not limited to installation. We received in-depth training for operators and maintenance personnel, and the post-implementation support was reactive and efficient. We resolved a sensor alarm within one hour, during a night shift, without affecting production.