The Farmsort.one optical precision sorter, incorporating industrial cameras by IDS Imaging Development Systems, utilises a 1.5-metre inspection section to categorise potatoes by size and quality, offering up to five grading levels in one pass.
As agricultural sectors face increasing quality requirements and staff shortages, there is a pressing need for advanced sorting solutions that transcend traditional pass/fail systems. Innovations that ensure multi-grade sorting based on size and quality demonstrate reliability in ongoing operations.
Addressing rising quality standards
Central to the Farmsort.one system is the optical inspection of each potato multiple times along its 1.5-metre inspection section.
Depending on the setup, two or three IDS industrial cameras view the constant flow of produce from varied angles. Unlike conventional systems that require each tuber to rotate freely for a complete inspection, this system evaluates quality through repeated inspections and controlled handling, providing consistent results even amidst challenges like foreign material or residual soil.
Delivering consistent results
Farmsort.one efficiently processes up to two tonnes per hour into as many as five grades
"We did not want a spot assessment like those used in many conventional systems on the market, but rather a controlled inspection over a defined distance," stated Jan Kiwitt, Project Manager at schmiede.one. "The combination of a guided conveyor system and multiple inspections enables reliable detection of quality characteristics while maintaining a consistent throughput."
Designed for both unwashed and washed potatoes, Farmsort.one efficiently processes up to two tonnes per hour into as many as five grades. Its core is a fully electric, conveyor-based track system previously utilised in large industrial settings, ensuring precise handling, lower maintenance, and reduced energy use compared to pneumatic systems. This precision and consistent result extend to the challenging conditions often encountered with unwashed potatoes and foreign materials.
Streamlined visual inspection
For visual inspection, schmiede.one employs IDS industrial cameras, allowing multiple captures of each potato along the line. These USB3 Vision cameras offer easy integration and reliable performance across the inspection path. Depending on the system's configuration, two to three cameras are utilised, enabling processes like distinguishing foreign objects and identifying defects like wireworm holes, while tracking each item’s position for accurate sorting.
Systems are fine-tuned using the IDS peak SDK, allowing for meticulous parameterisation and focus adjustments. "In line-integrated sorting systems, reliability and integration security are key factors, alongside image quality," emphasised Jürgen Hejna, Product Manager for 2D Machine Vision at IDS.
Market-ready produce
Farmsort.one efficiently sorts potatoes into up to five quality and size grades in one pass
Farmsort.one efficiently sorts potatoes into up to five quality and size grades in one pass, allowing market-ready produce directly from the sorter. By removing the manual re-sorting step, formerly common with systems only differentiating defects, throughput rates between 1.4 and 1.7 tonnes per hour are achievable without sacrificing accuracy. Approximately 73% of users have notably reduced their manpower needs.
With its modular design, Farmsort.one offers flexibility, allowing expansion as needed with more sorting outlets or cameras. Its control system adapts to flexible signals, and optional remote monitoring permits parameter adjustments from afar. Part of the Grimme Group, the system is employed on over 50 farms, with support from established service networks ensuring uptime during peak operations.
Exploring future innovations
Further enhancements are being explored, including monocular depth analysis and multispectral inspection methods, aiming to reliably identify additional quality features. IDS cameras and software lay the foundation for these developments, promoting stability and repeatability in sorting technology.
The optical precision sorter uses multiple IDS industrial cameras along a 1.5-metre inspection section to classify potatoes by size and quality, with up to five grades produced in a single pass.
Rising quality requirements and labour shortages are forcing agricultural businesses to modernise their sorting processes. Those seeking to ensure product quality while reducing the burden on staff need more than a simple pass/fail separation system. What is required is multi-grade sorting that reliably classifies produce by both size and quality and has proven itself in continuous operation.
This is precisely where the Farmsort.one optical precision sorter comes in. It brings industrial inspection principles to small and medium-sized agricultural businesses, combining size grading and quality inspection in a single pass. In most cases, it eliminates the need for manual re-sorting altogether.
Rising quality requirements
At the core of the system is a 1.5-metre inspection section. Along this section, each potato is captured optically several times. Depending on the configuration, two or three industrial cameras from IDS Imaging Development Systems monitor the continuous product flow from different angles.
Unlike systems that inspect each tuber from all sides at a single inspection station, the assessment does not rely on every individual object rotating freely. Instead, quality is evaluated directly within the process, based on repeated inspections, redundancy and controlled product handling. This enables the system to deliver reproducible results even when foreign material or adhering soil is present.
Delivering reproducible results
“We did not want a spot assessment like those used in many conventional systems on the market, but rather a controlled inspection over a defined distance,” explains Jan Kiwitt, Project Manager at schmiede.one. “The combination of a guided conveyor system and multiple inspections enables reliable detection of quality characteristics while maintaining a consistent throughput.”
Reduced energy consumption
Farmsort.one sorts both unwashed and washed potatoes into up to five grades at throughput rates of up to two tonnes per hour. At the core of the system is a fully electric conveyor-based track system, a concept previously used primarily in large-scale industrial operations. Compared with pneumatic sorting mechanisms, it offers more precise product handling, lower wear and tear, and reduced energy consumption.
The controlled guidance of the produce forms the basis for consistent sorting results, even when processing unwashed potatoes, foreign material or crops harvested under challenging conditions, where free-flowing systems can lose accuracy. At the same time, it enables continuous operation regardless of labour availability.
Short transmission paths
For visual inspection, schmiede.one relies on industrial cameras from IDS. They capture each potato multiple times along the 1.5-metre inspection section, enabling objective quality assessment directly within the sorting process. For compact integration into existing sorting lines, USB3 Vision industrial cameras are used. Short transmission paths, straightforward integration and reliable image transfer ensure consistent inspection performance throughout the entire inspection section.
Depending on the specific configuration of the system, two to three IDS U3-3270CP Rev. 2.2 USB 3.0 Vision cameras are used. One camera classifies the objects and detects both foreign objects, such as stones, and small defects on the tubers, such as wireworm holes. Another camera tracks every single object along the conveyor belt. When used in conjunction with a rotary encoder, the position of each tuber can be determined with precision, enabling damaged produce or produce that does not meet specifications to be selectively removed.
Low-maintenance continuous operation
Integration is carried out using the IDS peak SDK, which supports reproducible parameterisation, correct camera mounting and precise focus adjustment. “In line-integrated sorting systems, reliability and integration security are key factors, alongside image quality,” emphasises Jürgen Hejna, Product Manager for 2D Machine Vision at IDS. “Reliable interfaces, long-term availability and reproducible camera settings are crucial for low-maintenance continuous operation.”
Compromising sorting accuracy
Rather than simply distinguishing between “good” and “bad” produce, Farmsort.one sorts potatoes by both size and quality in a single pass into up to five grades. Defective potatoes are removed via the first outlet, oversized potatoes via the second, while Grade A produce remains in the main product stream.
This results in market-ready produce straight from the sorter, eliminating the manual re-sorting step typically required when using systems that only separate defects. Under real-world operating conditions, many farms achieve throughput rates of 1.4 to 1.7 tonnes per hour without compromising sorting accuracy. As many as 73 per cent of users have eliminated manual re-sorting altogether, significantly reducing their reliance on sorting personnel.
Season-critical continuous operation
The system has been designed with a modular architecture. Growers can start with a smaller configuration and later expand the system with additional sorting outlets or extra cameras. The line control system is designed for flexibility and supports both 24 V signals and FlowControl. An optional remote monitoring capability allows sorting parameters to be adjusted and optimised remotely.
Farmsort.one is a solution developed within the Grimme Group and is already in use on more than 50 farms. Service and sales are supported by an established network, helping to ensure the system’s technical availability during season-critical continuous operation.
Additional methods for improving defect detection are being investigated for future applications. These include monocular depth analysis and multispectral inspection methods in the NIR and SWIR ranges. The aim is to reliably record further quality characteristics and to supplement visual sorting with additional objective criteria. Industrial cameras and Software from IDS provide the technical foundation for stable, repeatable inspection and enable the integration of camera-based quality assessment into compact sorting lines.
