How one machine solves pet food sorting for manufacturers

Enhancing efficiency and precision in pet food sorting has become a key priority. Optimum Sorting introduces an innovative 3-in-1 approach that combines camera, laser, and metal detection technologies into a single machine. 

This integrated system allows producers to identify and remove various defects accurately, streamlining the sorting process and helping to meet increasingly strict quality standards. Here’s a step-by-step look at how this advanced technique works.

Growing focus on optical sorting of pet food

Estimates suggest there are around 600 million cats and 900 million dogs kept as pets globally. With so many mouths to feed, pet food manufacturing has surged, and so has the need for quality and consistency. 

Today’s consumers expect their pets to be fed with care, often choosing food tailored to specific nutritional, dietary, or dental hygiene needs. As a result, pet food must meet standards increasingly similar to those in human food production.

Manufacturers must not only prevent non-consumable foreign objects (e.g., metal, glass) from reaching the end product but also eliminate cross-contaminants such as different kibble types or recipes. 

While traditional sorting methods typically rely only on color differences, the current market demands more advanced criteria, such as shape, size, texture, and composition.

Optimum Sorting’s technology allows manufacturers to meet these evolving requirements with one streamlined solution.

Step 1: Sorting through camera technology

In the first step of the sorting process, the high-resolution cameras from Optimum Sorting will do their job. These cameras, which are standard in the Novus sorting machines, can effortlessly detect deviations based on color, shape and/or size. Such deviations are most commonly found when sorting pet food, such as dry dog or cat kibble.

Pet food kibbles that vary in any aspect, such as color, shape, broken pieces, or size (too small or too large), can be effectively detected by the cameras. By concentrating on shape, size, and color, cross-contamination is minimized.

What does this mean? When a production line switches from one type of kibble to another, there is always a risk that kibble from the previous batch remains on the conveyor belt.

The deviating kibble is then blown out using high-performance compressed air valves and lands on a separate belt. This ensures that only the kibble that perfectly meets the consumer’s requirements and expectations is allowed to proceed to the next step in the production process.

Additionally, thanks to deep learning and AI-driven algorithms, the system can distinguish between subtle variations, identifying items that may visually resemble acceptable kibble but differ in other key characteristics.

Step 2: Sorting through laser technology

Next, laser technology enhances the sorting process by analyzing structural and biological characteristics using multiple wavelengths. This allows for the detection of differences invisible to cameras, such as subtle textural variations between similar-looking kibbles.

This step is especially useful during production line transitions between different recipes or ingredients, where composition rather than appearance is the key differentiator. Lasers are also effective in identifying foreign objects with similar color, but different material properties (such as wood, plastic, stone, or glass), that may pass undetected through the camera stage.

Step 3: Sorting with a metal detector’s touch!

As the final step, metal detection, referred to as ‘M-TEC’ at Optimum Sorting, is highlighted. This module is integrated into the frame of the sorters and detects metal pieces, as small as 1 mm, even when embedded within the kibble, or positioned underneath it.

Unlike standard magnet systems, M-TEC identifies ferrous, non-ferrous, and stainless steel contaminants, further minimizing risk and ensuring compliance with food safety standards.

Novus: a top choice for sorting pet food

The Novus belt sorter from Optimum Sorting offers a highly versatile solution for pet food optical sorting. Its unique configuration allows for the seamless integration of camera, laser, and metal detection technology. 

This 3-in-1 configuration reduces investment and saves valuable floor space, making it a smart choice for manufacturers seeking to modernize their quality control processes.

About Optimum Sorting

Optimum Sorting specializes in developing optical sorting technology, serving both food and non-food markets worldwide. They aim to optimize sorting efficiency, enabling our customers to maximize productivity and minimize (food) waste. 

With roots dating back to the 1980s, the company’s solutions – Magnus, Novus, and Ventus – are used across a broad range of products, from frozen foods and confectionery to pet food and minerals.

Their mission is clear: “Sorting smarter. Wasting less. Shaping tomorrow.”

More information: www.optimum-sorting.com (Pet food | Optimum Sorting)