Practical answers about optical sorters, belt materials, and how automated lines fit into a large apple packing facility.
High-speed cameras and laser scanners evaluate each fruit in a few milliseconds. On a typical 1.2-meter belt running at 0.8 meters per second, a single sorter module handles roughly 12 to 15 tons of apples per hour. The limiting factor is usually the infeed system, not the sorter itself.
The optical unit spots bruising, skin discoloration, stem and calyx presence, and size deviations. It also flags foreign material like leaves or small stones. Each defect category gets its own rejection threshold, so you can tune the line to your packing standard rather than accepting a one-size-fits-all setting.
Stainless steel handles heat, cleaning chemicals, and constant moisture better than polymer, which matters in Malaysian conditions. Steel belts also hold tension longer and resist stretching. Polymer belts are quieter and lighter, so they suit shorter transfer sections where weight and noise matter more than heavy-duty wear.
A complete line with infeed, two sorting modules, and packing stations runs about 18 to 24 meters in length. Width depends on belt size, usually 1.0 to 1.4 meters. You also need clearance for maintenance access on both sides, roughly 1.2 meters, so plan the room accordingly before installation.
Yes, most facilities keep manual packing stations for final grading and box filling. The automated sorter handles defect removal and size grading, while people manage the final visual check and packaging. This hybrid setup reduces labor pressure without requiring a full rebuild of your current floor.
Daily cleaning of the camera housings and laser windows takes about 20 minutes. Weekly checks cover belt tension, roller bearings, and air nozzle alignment. Monthly, you inspect the rejection chutes and calibrate the sensor thresholds. Most of this can be handled by your own team after a short training session.
Catalog
Three service tiers for apple processing facilities, from first installation to long-term line maintenance. Each option covers a different stage of your operation.
This package covers the essentials for a single sorting module: baseline calibration, belt alignment checks, and operator training on the control interface. It suits facilities that are adding their first automated sorter and need a clear starting point. The kit includes a documented inspection checklist and a follow-up visit to confirm settings after two weeks of production. Everything is scoped around one line, so the work stays predictable and easy to schedule.
View package detailsThis option is built for plants that already run manual sorting tables and want to move to automated lines without stopping production. A technician maps your current floor layout, identifies the best insertion point for the sorter, and coordinates the changeover during a planned shift break. The scope covers conveyor speed matching, sensor positioning, and a short handover session for your line supervisors. It is a practical way to introduce automation while keeping existing staff involved.
View package detailsThis package is for facilities that want scheduled maintenance and remote diagnostics after their sorting line is running. It includes quarterly belt inspections, camera lens cleaning protocols, and firmware updates for the optical sorting unit. A dedicated contact person handles your service requests and keeps a log of recurring issues. The arrangement is designed to reduce unplanned downtime during peak apple processing months.
View package detailsEvery Pepipommes installation is built around the specific demands of corporate apple packing floors. We focus on the functions that keep a line running at full capacity without bottlenecks, rework, or unnecessary downtime.
High-speed cameras and laser scanners inspect every fruit as it passes, flagging bruises, discoloration, and size deviations before they reach the packing station.
Belt speed and sorter thresholds are tuned to match your line's actual throughput, so the system keeps pace during peak harvest weeks instead of becoming the slow point.
Each sorter can be configured for different apple varieties and grade standards, letting you switch between export and domestic specifications without reconfiguring the whole line.
Stainless steel conveyor sections are rated for continuous food-grade operation and designed for quick washdown cycles between shifts, reducing cleaning time and water use.
Modular sorter heads and belt segments can be replaced individually, so a worn component does not force a full line shutdown or a complete conveyor replacement.
Sorting data is logged per batch and per shift, giving your floor supervisor a clear view of yield, reject rates, and variety performance without manual counting.