Camera-based precision sorting helps professionalise farm shops and family-run farms

Structured inspection along a defined inspection path

The core of the system concept is a 1.5‑metre inspection path. Along this track, each potato is visually inspected 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.

“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.”

Electric conveyor‑based sorting for stable processes

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.

Camera technology as an objective measure of quality

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.

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.”

Size and quality grading in a single pass

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.

Scalable line concept with long-term investment security

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 at 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.