Automatic sorting machines

Types of Automatic Sorting Machines

According to research, the sorting machine market size was valued at $12.59 billion in 2022 and is estimated to reach $20.90 billion by 2030, witnessing a CAGR of 6.66% according to a recent dataset.

An automatic sorting machine is a device that categorizes items based on preset standards like size, quality, color, or weight. It is an essential step in product processing and assembly for various industries and is beneficial from a cost-effective and time-saving point of view.

There are several ways in which materials can be sorted through automated systems. Industries use various automatic sorting machines that process different materials by customizing the machine's detection method and sorting mechanism.

• Artificial Intelligence (AI) and Machine Learning (ML)-based Sorting:

  With the advent of AI and ML, automatic sorting now includes cognitive abilities, such as learning from past sorting experiences to optimize future decisions. This can also involve behavioral analysis, where the sorting preferences are based on specific behaviors learned by the system.

• Conveyor Belt Automatic Sorting Machines:

  In this system, items are typically placed on a conveyor belt and are classified as they pass through various sensors. After detection, the goods are usually re-organized using a designated mechanism such as a push, pull or flop, stitch, sweep, or pneumatic transfer.

  This kind of sorting machine can be found in the food industry, where agricultural products are sorted out on a conveyor belt for abnormalities using color sorters that rely on advanced cameras and artificial intelligence to identify the proper coloring on fruits, vegetables, grains, and other such commodities.

  A high-throughput facility may support a belt width of 36 inches and process 100,000 pounds per day. With these capacities, the percentage recovery is typically 5 to 25 percent.

• Automated Tele-clinic Sorting Systems:

  Automated tele-clinic sorting systems are designed to improve efficiency by automatically routing incoming calls and queries to the appropriate healthcare professionals or departments. Such a system can prioritize critical medical situations over others that can be handled with more urgency and less immediacy.

  For example, a patient calling in with a concern regarding medication may not require an immediate response from a doctor and can be directed to a nurse who tracks and monitors a patient's medications and can answer clarifying questions. In this way, the doctor-nurse-patient relationship is strengthened, and a better user experience is achieved.

  These systems improve email management within the healthcare setting by making sure information is correctly sent and received, thus improving the overall practice's efficiency and standard of care.

• Pneumatic Automatic Sorting Machines:

  Pneumatic systems use air pressure and airflow to transport and sort items. This method is commonly used for small, lightweight, and dusty materials, such as grains, coal, and powder. In this case, it's done by creating air jets that blow the object in the desired direction.

• Optical Sorting Machines:

  Optical sorting machines are specialized devices used to separate and classify items based on visual characteristics, such as color, shape, size, and surface quality. Advanced imaging technologies such as cameras and sensors are typically used for this type of sorting to capture the object's image, which is then analyzed by computer algorithms to identify and classify it precisely. The objects that do not meet the preset criteria are then distinguished and removed.

  Optical sorting is commonly used in agriculture to inspect and sort food products such as fruits, vegetables, grains, nuts, and confectionery. It can also be used in recycling facilities to segregate recyclable materials from contaminants, in textiles to separate defective fabrics from healthy ones, and in manufacturing to quality control and sort electronic components, automotive parts, and industrial materials.

Specifications and maintenance of automatic sorting machines

Every type of sorting machine has unique requirements regarding usage and maintenance. Here are some automatic sorting machine types along with their specifications and maintenance tips.

• Fruits and Vegetables Sorting Machine

  Capacity - Up to 3 tons per hour.

  Available with 12, 16, or 20 lanes and with or without color sorting.

  Maintenance

  Periodic calibration and re-setting of sorting criteria are essential.

  Cleaning and checking for damage to the inspection belts and boards is necessary.

• Parcel sorting Automatic Sorting Machine

  Capacity - 12000 cartons per hour, with an accuracy of 98% at RRM

  Parcel sorting machines are used to classify and separate incoming and outgoing parcels based on predefined criteria, such as destination, size, weight, and other package attributes.

  Models include tilt tray sorters, cross belt sorters, bomb bay sorters, and others.

  Maintenance

  Daily inspections, weekly belt alignment checks, and quarterly lubrication of sorters are required.

  Replace any damaged or worn belts immediately. Remove any jammed items from the belts and not use drags or forks.

  Try to avoid spills and quickly clean them up so that no residues are left behind on the belts.

• Garbage sorting Automatic Sorting Machine

  The capacity ranges between 1-10 tons per hour, depending on the model.

  It uses belts, trommel screens, air classifiers, and other methods to separate different types of waste like metal, plastic, organic, glass, and e-waste.

  Maintenance

  Regular maintenance of components like air classifiers, trommel screens, vibrating, fans, and magnetic separators helps to improve their lifespan.

Uses of automatic sorting machines

Automatic sorting machines suit broad industries and applications. The following are some key uses of these machines:

• Parcel Sorting in Logistics

  In the logistics sector, automatic sorting machines are used to organize parcels and packages by different parameters. These include size, weight, shape, and destination. Sorting machines increase efficiency in the supply chain by streamlining the delivery process.

• Quality Control in Food Processing

  Food sorting machines have special features like X-ray detection. They check food products, including things like chips and veggies. The machine looks for things like broken pieces, weird shapes, and quality problems. When it finds something strange, it will sort it out. This kind of sorting helps food companies keep their good reputation and meet quality standards.

• Categorization in Libraries

  Libraries use book sorting machines to make it easy to put books back on shelves. These machines read the spine labels and decide where the books should go. Using a book sorting machine cuts down the time it takes to file books manually by a lot. It also helps library workers get the job done faster and better.

• Sorting Mails in Postal Services

  Automatic mail sorting machines make it easier for postal services to process and sort mail quickly and accurately. The machine reads the address and sorts the mail by the destination automatically. Using an automatic sorting machine helps speed up delivery. It also makes organizing the mail more precise than when done by hand.

• Sorting Waste in Recycling Plants

  Sorting machines have become crucial in recycling plants. They help pick out recyclable materials from mixed waste streams. This is done in an eco-friendly way. The machines identify different materials using sensors. After that, they separate them into the right categories. These include plastics, metals, glass, and organics. Material recovery facilities can improve the quality of their output and increase recycling rates with the help of waste sorting machines.

How to choose automatic sorting machines

There are a number of factors that buyers need to consider before purchasing or retailing an automatic sorting machine.

• Productivity and Capacity:

  Assess the machine's sorting speed (items per minute) and its capacity (maximum volume it can handle) to ensure they align with the business's operational needs.

• Item Compatibility:

  Check if the automatic sorter can handle the shapes and sizes of products. Verify that it can properly detect and classify the items the company intends to sort.

• Technology and Accuracy:

  Opt for sorters with advanced technologies, such as artificial intelligence and machine vision, which enhance sorting precision and efficiency. Buyers should get a machine with accurate sorting capability to minimize errors and ensure proper classification.

• Integration with Existing Systems:

  Ensure the chosen sorting machine can seamlessly integrate with the company's current production lines, software systems, and other equipment to enable smooth operations and data exchange.

• Scalability and Flexibility:

  Select a sorting solution that can easily scale up or down to accommodate changing business needs and adjust to different sorting criteria as the company grows or market demands fluctuate.

• Maintenance and Support Services:

  Consider the machine's maintenance requirements and the availability of technical support services. Opt for suppliers that offer reliable support, spare parts availability, and comprehensive maintenance contracts to ensure smooth operations and minimal downtime.

FAQ

Q1: How does an automatic sorting machine improve production efficiency?

A1: The key to automatic sorting machines' impact on production efficiency lies in their capacity to streamline workflows, minimise manual intervention, and enhance the pace and precision of sorting.

Q2: What are the primary sorting methods used in automatic sorting machines?

A2: The foundational principle of sorting remains unchanged, but the methods have evolved. The primary sorting methods are classified according to the material nature and automated technology; they include pneumatic, optical, electronic, mechanical, magnetic, and acoustic sorting.

Q3: Can an automatic sorting machine be integrated into an existing production line?

A3: Factors like the dimensions of items being sorted, sorting speed requirements, and the characteristics of materials needing to be sorted should be considered when choosing an automatic sorting machine for integration. It's crucial to ensure that the chosen sorter aligns with the specific needs of the production line.

Q4: What are the maintenance requirements for an automatic sorting machine?

A4: Automatic sorting machines have different models and various maintenance demands. Typically, routine inspections, lubrication, parts replacement, and cleaning are necessary to guarantee that the machine operates correctly and stably.