Rice Color Sorter
SORTEK Rice Color Sorter is Your Affordable Rice Sorting Solution
SORTEK Rice Color Sorter provides a high-precision rice sorting solution for all types of rice. Whether it’s freshly harvested rice or long-term storage rice in the warehouse, processing plants are always unable to avoid problems such as lesions, impurities, and breakage.
These problems are also threatening our food safety at all times. Sortek Rice Color Sorter is designed to separate fine rice from the original mixture, which can solve food security problems and improve production efficiency.
SORTEK Rice Color Sorter is not only used for regular rice like long-shaped rice, round-shaped rice, and sticky rice, but it is also used for other types of rice such as black rice, yellow rice, rose rice and even high glutinous rice. The sorting accuracy at one time is close to 99.9% and single chute sorting capacity is less than 1.3 ton per hour.
SORTEK provides a complete sorting solution to farm and large scale rice processing plants. Contact us and let us help you customize the best sorting solutions.
Why Trust Sortex Rice Color Sorter ?
Rice Color Sorter: Ultimate Buying Guide
This guide covers everything that you need to know about rice color sorters.
First, I’ll show you why using rice color sorter is more important than traditional sorting methods. Then, I’ll help you choose the right rice color sorter that will help you get rid of defects and impurities from raw rice before packaging it.
Let’s jump in to learn more about rice color sorter.
Chapter 1: What is Rice Color Sorter?
1.1 What is the Rice Color Sorter?
A rice color sorter separates rice based on color differences in raw rice. These differences could have arisen from anomalies such as:
- Bits of stones
- Black rice
- Half-husked rice
- Bad rice
A Rice color sensor has a high-resolution optical color sensor that drives a mechanical sorter to automatically separate different granular materials, and sort heterochromatic particles out of the raw rice batch.
In short, a rice color sorter removes impurities in rice so as to improve rice quality.
1.2 Advantages of Color Sorting Machine
Below is a summary of the benefits of a color sorter machine.
The quality of food products has been revolutionized by color sorting machines in a big way. Through a color sorter machine, a manufacturer can monitor the quality of products easily, and hence launch only high-quality products in the market.
Color sorter machines are automated, and hence do not retard the speed of quality check. Actually, this machine speeds up the entire quality assurance process by getting rid of human effects like strikes and fatigue.
A manufacturer can decide and change the extent of texture and color difference that a color sorter machine should reject. This is an added control over products, as items can be sorted into multiple categories.
- Return on Investment (ROI)
A color-sorting machine gives the investor an incredible ROI. These machines are almost a one-time investment that needs low maintenance.
Just like any other automated machines, rice color sorters reduce management issues and labor costs. They also minimize the accepted error margin associated with human errors to a huge extent.
1.3 Why Rice Color Sorter?
When it comes to product marketing, good presentation is key. Marketers have to look at their products from the customer’s eyes/perspective. Looking at this angle helps in knowing how best a product should be packaged. Although some packages showcase a pathogenic or artistic product view, others give a direct product content view through a transparent part.
Rice and grain/seed manufacturers, for example, package their products with a substantially reasonable transparent part. A customer can easily determine quality through visual perception, and Specks of impurities are a turn off to anyone intending to buy the product
A rice color sorter machine features automated technology that helps in achieving the intended uniform color and texture. It achieves this by scanning a line of rice grains using a super-high-speed camera and ejecting low-quality grains and impurities. This process is useful in sorting the grains into two: Those meant to be released to the market, and the rejects.
Chapter 2: Types of Color Sorters
There are two types of color sorters: Chute color sorters, or Belt-type color sorters. In this chapter, we will look at the features, benefits, and drawbacks of each. Read on to know which type is best for sorting rice.
2.1 Chute-Type Color Sorters
Chute type color sorters are mostly common for food and their prices lower. They have higher capacities, and products can be seen from both sides easily. This is crucial when a dehulled grain has hull at one side only.
Chute type sorters are applicable for specific products because the chutes are designed with specially formulated channels for such type of material depending on the sizes, kind, and materialshapes. For instance, 5mm chutes are best for plastic granules and grain rice. Flat chutes work well with plastic flakes like pet and milk bottle flakes.
On a Chute-type color sorter, the material slides on the chute due to gravity and causes the collision, friction, and larger vertical movements. This increases the broken material ratio.
However, if the material has a lower probability of defects, a chute type sorter is much better
2.2 Belt-Type Color Sorter
Unlike the chute-type sorter, the belt type sorter gives a smooth transmission which is stable and does not bounce the material. However, the belt type sorter is not good for high capacity materials.
Belt color sorters are good for applications in food processing companies of seafood, nuts, dried fruits, dries nuts, vegetates, and freeze-dried fruits,
The material of the belt type color sorter’s bin smoothly transfers to the outlet which is equipped with a high camera acquisition card. This camera spots the color difference of good material and impurities, after which these are separated.
The benefits associated with belt color sorters are:
- A lesser ratio or broken material- this is because the machine stays relatively stationary, and the material is hence not subjected to friction and collisions as is the case in a chute-type color sorter
- A wider range of application
- Higher sorting accuracy
2.3 Which is the Ideal Rice Color Sorter?
For a rice color sorter, we recommend the Chute-Type Sorter. This type can complete requirements of rice sorting and is more economical than the Belt-Type color sorter. Its design and 5mm chutes are specifically meant for grains such as rice, and since chute type sorters have higher capacities, they are good for sorting high volumes of rice.
Besides, rice has a lower percentage of the defect, and you need not worry about it being broken up by a chute-type sorter.
Another reason why a chute-type sorter is the best rice color sorter is that it is designed in a way which material can be seen from both sides. This makes monitoring easier and quality control convenient.
Chapter 3: Main Parts of Rice Color Sorter
Rice Color sorters are made of different components including the feeding hopper vibrating feeder, background plate, chute slide, silos, detection camera, air compressors, air nozzle, purifiers, and fillers. Buttoday, we will only look at the four main components.
- The Feeding System
The feeding system is comprised of the hopper, the vibrating feeder, and chute slide among other components. The rice meant to be sorted moves from the hopper into the vibratory feeders. These vibratory feeders are arranged in a manner that enables the material to row in continuous filaments automatically. After accelerating on a steady speed through the chute, rice falls into the photoelectric detection sorting areas as well as sorting spray zones.
The amount of vibration can be controlled within the color sorter unit time production control. Air humidity might affect the rates of air sliding along each other hence affecting the accuracy of rice color selection. At times, there is a need for sorter restoration by inducing suitable temperature levels of drying functions.
- Optical Systems
This is the core part of the acolor sorting machine. It is the source of light, a background plate, the CCD camera, as well as crucial related auxiliary equipment components. The optical system offers uniform illumination on the rice being tested and the background plate.
Research proves that LED light works best in sorting out the rice.
The detection area within test materials reflects light into electric signals. The CCD camera detection is sealed so as to prevent stray light from getting into the CCD camera, as this would compromise quality. There is a broad background of an electronic control system meant to provide a reference signal. The optical system has reflective characteristics and reflective properties to substantially differentiate the quality products from the rest.
- Sorting System
The parts of this system are hopper, air compressors, jet valves, and air purification filters. The main purpose of this system is optically separating good and bad material as identified by the optical system. The sorter machine has an air compressor that continually provides compressed air. This works with a filter in order to improve sorting accuracy and prolong the machine’s life.
Rice moves through the post-injection nozzle in high speeds. The silo space should hence be taken good care of. Dampening measures are employed on the hopper to minimize the chances of rice playing in the bin. The sorter’s accuracy is affected by the nozzle spacing and number of nozzles.
- Remove/Ejection System
Once digit signalsare received from the CPU, ejectors respond quickly, releasing the compressed air. The air changes the rejected material movement route to the reject bin.this separates the bad grains from the good.
A color sorter’s efficiency is usually at its best when all these parts or systems are working together. However, you should not buy an entirely new color sorter if one of these parts is not working. You can get spare replacement parts from a manufacturer, distributor, or agent.
Chapter 4: How Does Rice Color Sorter Work
The processing of rice starts at the milling plant. Here, harvested grains go through a production line whereby rice gets boiled, dried, husked, destoned, shelled, and hulled. From this point, rice is taken into a color sorter machine. The mixture of rice moves through an elevator belt into a hopper on top of the sorting machine from where it flows down along chutes in the color sorter. The flow is streamlined and scanned by the sorter’s SSD sensors. Once the camera detects a color defect it instructs ejectors that are machine-fitted to open a nozzle connected tovalves with compressed air. The air then shoots the defected rice out the types of rice defected include:
- Yellow rice
- Mouse dropping
- Immature grains
- Chalky rice
- Black-tipped rice
4.1 The Working Principle of Rice Color Sorter
At the moment, there are two main rice color sorter machine sensors in the market
- The optical type
- The CCD type
Regardless of the type, the basic working principle is the color difference between good and unwanted/ bad rice. The color sorter machine translates the photo signal into an electronic signal through a photosensor and other complex elements.
To start with, there are those termed as good material and other bad material. As a result, there is a difference in the electronic current resulting from good materials, and that from bad materials.
The color sorter adjusts some degree of electronic current for good materials into “safe mode”. Current on unwanted or bad materials is termed as “dangerous”. When the current is “safe”, nothing happens on the rice. It falls down successfully to the accepted outlet. However, when the electronic current is “dangerous”, the ejector is driven to blow away the bad rice into the unwanted materials.
- A pile of grains gets into the hopper from the vibrating feeder.
- The feeders play the role of spreading and leveling the grain into a single-layer flow.
- The control area has two video cameras installed on the sides. Now, the single stream of rice is scanned by those cameras.
- Data generated from the video cameras are used in the arithmetic unit and gets analyzed in real time.
- From the signal image analysis results, valves open generating an airflow pulse.
- Compressed air pulses with pressure about 0.4 to 0.6 MPa is generated in a millisecond duration. This pressure blows the unwanted grain into a corresponding receiver module.
4.2 The Factors Affect the Sorting Capability
The accuracy of a rice sorting system depends entirely on two main factors.
- The strength of image processing and image classification systems used.
- The Efficiency of mechanical feeding and sorting systems
Once the feed’s rate is increased, errors are likely to increase because of kernels’ close proximity to each other.
A typical camera needs about 17 milliseconds for capturing and transferringone images to the controlling systems. This means that if the separation of kernelsis by less than such atime period, they will not be imaged accuratelyor will be entirely missed.
In addition, kernels that are very close to each other could end up being diverted together by one air blast. A valve should be open at least for 5 milliseconds so as to account for the potential variation of a kernel position in regards to an air blast.
While output increases with an increased kernels feed rate, accuracy reduces.
An enhanced output with slightly reduced quality may be tolerated though. But feed rates should be well adjusted to maintain high-quality levels, while still offering a convenient amount of output.
Chapter 5: Rice Color Sorter Machine Installation
After buying a rice color sorter machine and it’s now shipped to your preferreddestination, what follows is installation. Some sellers such as Sortek will give you complete after sales services inclusive of installation, and this could make things easier.
However, what if you want to transfer your sorter from one place to another, or, your seller didn’t offer installation?
On this chapter, we will guide you on how best to install a rice color sorter machine, precautions to take, and the accessories you will need.
Let’s get honest with each other. Installing a rice color sorter is quite daunting. However, it gets much easier if you have the right conditions and accessories. This means that on top of buying the machine, it is important you invest in some tools such as:
- Air compressor
- Metal support/ Mounting platforms
- Elevator/ Lifting machines
- Tools Necessary
- gas storage,
- gas filter
Every color sorting machine will need a separate metal support platform as well as material lifting systems.
The metal support platform lifts the machine to some height, and this facilitates material collection at the outlet, while the purpose of theelevator/ lifting system is delivering material to the hopper.
Read on to know the importance of the other accessories.
5.2 EquipmentInstallation Diagram
Machine Installation Guide and Recommended Condition
Color sorters come with an installation diagram and operation instructions with its packaging. Hence, mounting and assembling is easy.
The installation site ought to be flat and solid. the constructed working platform too ought to be free from strong vibration sources such as white rice graders and polishing machines
Install anElevatorbefore the color sorter to minimize damages on the color sorter resulting from falling hard or welding objects.
The compressor tank’s installation site needs to be far from the crowd to minimize noise pollution and injuries. The air tank and compressor should also be in a dry and ventilated place to maintain clean and dry compressed air.
The temperature should be ambient. An Air Compressor might help in areas with high temperatures and places with low temperatures
External light affects color separation directly. It is therefore important you put your color sorter in places with no strong light. The light should be just enough for separation and maintenance.
There should be adequate space around your color sorter. Space is important for debugging and maintenance. Space should be at least 60cm.
Grounding the sorter significantly prevents lightning strike damage to the sorting machine. It also minimizes personal damage resulting from current leakages from misoperation. It is hence advisable that you embed ground wire prior to welding the platform.
Strong electromagnetic interference such as high-frequency transmission and electric welding are forbidden around the site
Unpacking and Examination
When unpacking a color sorter machine, you should consider safety first. Avoid unnecessary damage, and count all spare parts based on the list in the box. Keep all parts safe.
- Place the color sorter machine on a metal or solid and enclosed platform of hard ground or railing. This should be above 1.8 meters above the ground. Passages of 50-60 cm or more ought to be left around the machine for easy patrol, operation, and maintenance.
- The outer material inlet should accurately correspond to the inlet pipe
- Carefully check that the color sorter’s lifting rings are reliable when installing and fixing the frame. This will recuse the chances of accidents when lifting the sorter machine.
On this stage, it is imperative you follow wiring directions and precautions to cut down the chances of electric shock or physical injury.
The air compressor should be installed close to the machine. Pipes at most 10m of length should be used, based on the practical situation. A three-phase (380V, 60A) should be prepared
Please note that improper installation could lead to mechanical faults or personal injuries.
5.3 Technical Support
Installing a rice color sorter on your own for the first time can be somewhat daunting. So, why not get technical support from experts? First, most sellers will offer free installation as they have agents in almost all cities. You can hence ask your seller to offer you a professional engineer or team onsite to help in installation, and operation training.
Getting your machine installed by an expert is important for a number of reasons:
- An expert will help you choose the best installation site with ideal conditions
- Good electrical, support, and mechanical conditions preparations
- A more accurate installation for accurate sorting results
- Reduction of losses associated with armature installation
- Reduced personal injuries
With such benefits and reduced inconveniences, it is only fair that you seek technical installation, repair, and maintenance support. Fortunately, most color machine experts are readily available around the globe.
Chapter 6: Sortek Rice Color Sorters For Rice Sorting
SORTEK is one of the leading manufacturers of different color sorters. They make belt color sorters, chute color sorters, X-ray color sorters, and CCD Color Sorters among others.
With 20 years of manufacturing and R&D experience, Sortek has managed to create a solid reputation in offering customized color sorting solutions to its customers. Here, we will look at two of SORTEK’s incredible sorting machines.
6.1 SR-1 Mini Rice Color Sorter
A single chute color kind color sorting machine, Sortek Mini Rice Color Sorter has an efficient design for separating fine things from raw materials.
This machine has only one chute. The single chute is divided into different channels based on the material’s diameter. 64 of these channels are the regular model, and the machine can match several products with diameters ranging from 1-50mm.
Sortek Mini Rice Color Sorter sorts tiny farm particles such as rice, grains, coffee beans, white or black beans, and tea. Others are dry shrimp’s nuts, dry vegetables, and dry fruit. It can also be used to classify plastic material, sugar, and salt.
The sorting capability of Sortek Mini Rice Color Sorter is around 400 to 500kgs, all depending on the type of material being sorted. Its sorting precision is close to 99.9%. With the bad: good carryover rate is more than 10:1.
SORTEK Mini Rice Color Sorter’s regular voltage ranges from 110-380V/50Hz.
Such a color sorter can be configured and used in North America South East Asia, and Europe among other areas.
SORTEK Mini Rice Color Sorter comes with two distinct sorting modes:
- Normal sorting
- Reverse sorting
Both of these modes can separate material from a raw mixture. However, the difference is in the raw material. Once the rate of a defected material is high, the reverse sorting mode becomes better. Normal mode works well for normal defected mode rates. The Sortek Mini Rice Color Sorter cannot run in both of these modes at the same time though. This implies that if a mixture has many impurities, it will need to be screened a number of times.
A Sortek Mini Rice Color Sorter will need specific supporting equipment such as gas storage, air compressors, lifting machines, gas filter, mountain platforms, and so on.
Air compressors put compressed air into gas storage tanks, and that air is released once the nozzle gets a rejection signal. Using the process, the air filter cleans the air and reduces damages that impurities cause, thus prolonging service life.
The Sortek Mini Rice Color Sorter has been approved by the CSA and CE. All Sortek machines comply with local voltages.
Key components and features of the Sortek Mini Rice Color Sorter
- Material Hopper – this serves as the entry point of materials to the sorter
- A wide chute style for maximizing capacity
- High accuracy in rejecting defected things
- A vibratory feeder that makes sure that sorted material arrive evenly in the chute without overlapping
- Perfect transfer of material to the sorter’s screening area
- A high-resolution sensor on CCD camera for recording reading and recognizing RGB and saturation details
- As a brand Color Sorter, Sortek mini color sorting machine has been approved by both CE and CSA.
- Features a CPU with excluded commands
- LED light to offer a good light fill for products imaged.
- The sorter executes CPU-issued commands
- An air compressor and filler for providing the ejector with constant power.
- This sorter is sold with a 2 years warranty, and the seller offers complete after-sales services.
6.2 Sortek Multiple Chutes Rice Color Sorter
Sortek Multiple Chutes Rice Color Sorter
The Sortek Chute Color sorter machine comes with 1-12 chutes customization. It has a high performance and comes has a multi-color sorter and single-layer color sorter.
The Sortek Multiple Chutes Rice Color Sorter is also good for tiny products like beans, flax, minerals, plastic particles, and so on. It is commonly used in food processing, distribution, waste management, and recycling, plastic, and chemical industries.
The Sortek Chute Color Sorter plays sorting and grading functions.
The sorting function is meant to diagnose defective, deformed, and broken objects from raw materials. Grading is needed for fine screening.
The SORTEK Chute Color Sorter has many screening capabilities for a wide range of products. Generally, it is about 0.2-3t/h for each chute depending on different materials. It has a color sorting accuracy of at least 99%and a 10:1 Bad: Good carryover rate. Sortek offers different voltage ranges of color sorters in order to suit different markets. For example, the voltage required for American markets is 240v, while that for Europe is 220v. The SORTEK Chute Color Sorter can also be configured with voltages of 380V and 415V.
SORTEK Chute Color Sorter features two different sorting modes. These are the normal and invert sorting. Both of these modes can be applied to separate quality materials from raw mixtures, but differ a little.
Materials with small defects and impurities are best handled by the normal sorting mode, while the reverse sorting mode is food for materials that have huge proportions of defects and impurities. However, these two methods cannot be applied at the same time.
The SORTEK Chute Color Sorter comes with different structures, including the multi-layer color sorter, and the single-layer sorter. These layers are independent sorting units, and each unit could choose a separate sorting mode. The sorting capacity is generally dependent on the sorting machine’s number of sorting units. The Sortek Chute Color Sorter can divide products into different grades
The SORTEK Chute Color Sorter comes with full-color screening technology and unique image correction technology. Unique image correction automatically corrects distorted linear images resulting from signal errors in the image collection.
The regular optical color sorter then sorts of raw materials based on RGB color difference. The sorter has another camera to collect information on image saturation. These technologies enhance sorting accuracy.
Sortek Chute Color Sorter has a CCD camera as well as integrating light. It makes use of high tech photoelectric diagnostic system for ease in classifying heterogenic particles.
Chapter 7: Repair and Maintenance of color sorters by ourselves (DIY)
Just like any other household or an industrial machine, color sorters need good maintenance for enhanced efficiency and more life. On our final chapter, you will learn how to maintain a color sorter on a daily, weekly, and semi-annual basis.
Suitable cleaning guidelines are highlighted, and you will learn how to replace wearing parts by yourself.
7. 1Maintenance and Repair
7.1.1 Maintenance/ Repair on Each Working Date
Prior to doing maintenance, use air guns to clean sorting boxes and channels. As you use the air gun to clean the machine’s sorting box, ensure that the air gun does not blow in the direction of the nozzle.
- Inspect the signal indication. This should include alarm indication and work instructions, as well as the ejector case action
- Do an inspection on the air pressure, air compressor, the oil temperature and check whether the sound is abnormal. On each working date, drain off the compressor’s water a minimum of three times.
- Shut the machine down for 15 minutes, power off the air compressor and power switch. Drain the air compressor’s water off completely
- Clean the channel, ejector, and sorting box’ sediment using the air gun.
- Using the air gun, clean the machine’s interiors, hopper, vibrator, and the ash scraping device
7.1.2 Weekly Maintenance/Repair
- Check the wiper brush’s cleanliness
- Check the filter
7.1.3 Maintenance/Repair After 6 months
At least replace the compressor oil one time
It is important to keep the sorting machine clean. Dirt could reduce its efficiency in sorting out your rice accurately. Additionally, a machine’s probability of being faulted is increased by working in a dirty state. Below are important cleanup steps.
- Avoid using scrapper, wool, or corrosives on any part of your machine.
- As you clean your machine, be keen not to damage its vibrator’s surface, lenses, or special parts
Cleaning the Sorting Box Glass
Moist a soft cloth in alcohol to wipe the glass inside and outside the sorting box.
You can also moist soft cloth with alcohol and sandwich it between the cleaning glass and brush, then run the wipe function for best cleaning results.
Cleaning the Sorting Box Lamp
Start by disassembling the lamp of your sorting box. To clean, moist soft cloth with alcohol and pass it through.
Cleaning the Camera Lens
The soring box has gun air you can use to blow debris and dust on camera lens away.
Gently clean the machine’s channel with a soft and clean cloth
Cleaning the Cylinder Guide
Utilize a clean and soft wipe
Background Board Cleaning
Moist a soft cloth with alcohol, and open the machine’s sorting box. Wipe the background board with this gently.
7.3 Replacement of Wearing Parts
- Wipe brush replacement
Dial the stopper plate up at the bot side of your wipe brush. To rotate pinch the adjust rack. This deviates from the glass direction. From there, remove down the wiping brush.
- Wiper cylinder Maintenance
To remove the machine’s wipe cylinder for maintenance unscrew all screws on the rear fuselage’s beam path. This is where the cylinder is installed.
- Replacing the Air Filter
- There are four screws on the sorter’s filer. Unscrew them all
- Remove the filter and replace with the new one.
- screw back the 4 screws