Frozen Fruits Optical Sorter Showdown Tomra vs Key Technology

An optical sorter is a crucial investment for any fruit processor. The choice between industry leaders like Tomra and Key Technology often depends on specific operational needs. Tomra's sorters excel at removing the finest defects from high-volume frozen blueberries. Key Technology's VERYX, however, presents a versatile and robust solution for both fresh and frozen fruit processing.

The global frozen blueberry market is expanding rapidly. This growth underscores the need for efficient sorting technology.

A frozen fruits optical sorter must deliver quality and efficiency. Selecting the right machine requires a careful evaluation of its capabilities against your production goals.

Direct Comparison: Critical Sorting Metrics

   

Processors evaluate optical sorters on a few core performance indicators. These metrics directly impact product quality, operational efficiency, and profitability. A detailed comparison reveals the distinct strengths of Tomra and Key Technology in these critical areas.

Defect Detection and Sorting Precision

Precision is the foundation of quality control. An effective sorter must identify and remove a wide array of defects, from foreign material to subtle product imperfections.

• Tomra leverages advanced imaging systems and proprietary software to achieve exceptional precision. Its sorters excel at detecting challenging defects in frozen blueberries, such as pieces of stem, soft or discolored berries, and even unripe fruit. The integration of AI platforms like LUCAi allows the machine to learn and adapt, continuously improving its ability to distinguish between good fruit and the finest defects.

• Key Technology designs its VERYX platform for maximum versatility. These sorters combine multi-sensor technology, including high-resolution cameras and lasers, on a single platform. This allows processors to target a broad spectrum of defects based on color, size, shape, and structural properties. The system's flexibility makes it highly effective for operations that handle both fresh and frozen products, each with unique defect profiles.

Yield Protection and Product Recovery

Maximizing yield is paramount for profitability. A sorter's value is measured not only by the defects it removes but also by the good product it saves. False rejection—the incorrect removal of acceptable fruit—directly cuts into revenue.

Both manufacturers engineer their systems to minimize this loss. Tomra's technology demonstrates remarkable accuracy in this regard. The Tomra 5C optical sorter, for example, boasts a false reject rate of less than 1%. This level of precision ensures that good, sellable fruit remains in the product stream, maximizing the return on every harvest.

Note: A low false reject rate is a direct contributor to a processor's bottom line. Reducing product loss by even a single percentage point can translate into significant financial gains over the course of a season.

Key Technology's VERYX sorters also prioritize yield protection. Their intelligent ejection systems work in concert with advanced detection algorithms. The system precisely targets and removes individual defects without disturbing the surrounding good product, safeguarding valuable fruit from being unnecessarily discarded.

Throughput and Processing Speed

Processing speed, or throughput, dictates a plant's total output capacity. The ability to sort high volumes of product quickly without sacrificing accuracy is a key competitive advantage. A modern frozen fruits optical sorter must meet demanding production schedules.

Key Technology offers a range of VERYX models to meet diverse capacity needs. The VERYX B140 is well-suited for lines running at 5 to 10 metric tons per hour. For larger operations, the VERYX B210 model provides a massive capacity, processing in excess of 23 metric tons (over 50,000 lbs.) of product per hour. This scalability allows processors to select a machine that perfectly matches their line speed.

Tomra focuses on maintaining sorting precision even at extreme velocities. The company achieves this through a powerful combination of technologies.

• High-Speed Ejectors: Ultra-fast ejection modules remove defects with pinpoint accuracy at high speeds.

• Powerful Image Processing: Advanced processing units analyze a massive number of particles in real-time.

• AI-Driven Adaptation: Self-learning algorithms continuously refine sorting parameters to adapt to product variability, ensuring consistent accuracy as throughput increases.

This integrated approach allows Tomra sorters to handle high throughputs while minimizing the risk of valuable product loss, a crucial factor when sorting small items like frozen blueberries.

A Superior Frozen Fruits Optical Sorter for Blueberries

   

Blueberries present unique sorting challenges, whether fresh or frozen. Their small size, delicate nature, and subtle defects demand specialized technology. A processor's choice between Tomra and Key Technology often hinges on which state of the fruit—Individually Quick Frozen (IQF) or fresh—is their primary focus.

Performance on Frozen (IQF) Blueberries

Sorting IQF blueberries is a high-stakes process. The frozen state can mask defects, and the product's brittleness requires precise ejection to avoid shattering good fruit. Processors need a frozen fruits optical sorter that delivers both accuracy and efficiency.

Tomra has engineered its machines for exceptional performance in this environment. The company's latest generation of Pulsed LED sensors, combined with AI-powered processing, allows its sorters to peer through surface frost and identify underlying issues. The TOMRA 4C sorter, for instance, achieves a remarkable false reject rate of less than 0.5% with IQF products. This level of precision minimizes waste and maximizes the profitability of premium frozen fruit lines.

Key Technology approaches the IQF challenge with a focus on adaptability and customization. The VERYX platform is a modular system built to meet specific processor needs.

• Its recipe-driven operation allows operators to save and recall sorting parameters in seconds. A line can switch from sorting frozen peas to IQF blueberries with a simple command.

• Each VERYX sorter can be configured with a unique combination of sensors, lighting, and ejection systems tailored to a processor's specific products and quality objectives.

• Advanced machine algorithms within the VERYX 2.0 architecture power a state-of-the-art electronic sort engine, ensuring it can handle the unique demands of various frozen goods.

This makes the VERYX an excellent frozen fruits optical sorter for facilities that process a diverse range of products throughout the year.

Performance on Fresh Blueberries

Fresh blueberries require a completely different approach. The primary goal shifts from defect removal to gentle handling. Preserving the delicate waxy "bloom" on the berry's surface is critical for shelf appeal and extending shelf life.

Pro Tip: The natural bloom on a blueberry is a key indicator of freshness for consumers. Aggressive handling can remove this bloom, making the fruit appear old and reducing its market value.

Tomra addresses this need with its KATO 260 system, a solution designed specifically for the gentle sorting of fresh blueberries.

1. Gentle Distribution: An automated Tray Tipper ensures an even, consistent flow of fruit onto the line, preventing bruising from surges.

2. 360° Inspection: A unique rolling conveyor system gently singulates and rotates each berry. This allows cameras to perform a complete surface inspection without damaging the fruit.

3. Soft Packing: Integrated packing systems, like the CURO-16, use low drops and minimal transitions to carefully place the sorted berries into clamshells.

Key Technology's VERYX platform also provides strong performance for fresh blueberries. Its multi-sensor technology effectively identifies under-ripe, soft, or damaged berries. The system's true strength lies in its versatility. A single VERYX machine can be programmed to run fresh blueberries during harvest season and then be reconfigured to run IQF blueberries or other frozen products in the off-season. This flexibility offers significant value for processors who need one machine to do it all.

Beyond Sorting: Operational and Financial Factors

A sorter's performance extends beyond its technical specifications. Day-to-day usability, maintenance requirements, and long-term financial impact are critical considerations for any processing facility. These factors often determine the true value of the investment.

Ease of Use and Software Interface

Modern sorters require intuitive software to maximize operator efficiency.

• Tomra equips its machines with the TOMRA ACT user interface. This icon-based system simplifies operation and reduces the learning curve for new staff. The interface provides clear visual feedback on sorting performance, allowing for quick adjustments.

• Key Technology focuses on operational flexibility with its VERYX software. The system is recipe-driven, enabling operators to save and load sorting parameters for different products. This feature is invaluable for plants that switch between various fruits or between fresh and frozen runs.

Sanitation, Maintenance, and Uptime

Downtime for cleaning or repairs directly impacts profitability. Both manufacturers design their equipment for maximum uptime. They build machines with open-frame designs and sloped surfaces. This construction prevents water from pooling and simplifies washdown procedures. A well-designed frozen fruits optical sorter must withstand rigorous, frequent sanitation cycles. Durable components and easy access to key parts ensure that maintenance is swift, keeping the line running.

Total Cost of Ownership and ROI

The initial purchase price is only one part of the financial equation. Total Cost of Ownership (TCO) includes installation, training, maintenance, and operational costs over the machine's lifespan.

ROI Insight: Return on Investment (ROI) is often realized through increased yield and reduced labor costs.

Tomra's premium systems deliver ROI by minimizing false rejects and capturing the highest-value product. Key Technology's VERYX platform provides a strong ROI through its versatility, allowing one machine to serve multiple processing needs and adapt to changing market demands.

Tomra sorters excel in high-volume, specialized frozen applications demanding maximum quality. Key Technology offers superior versatility and value for processors handling both fresh and frozen fruit.

Decision Checklist:

• Is your primary product fresh or frozen?

• Is maximum throughput or ultimate defect removal the top priority?

• What is your budget for investment and long-term maintenance?

FAQ

Which sorter is better for IQF blueberries?

Tomra sorters offer superior precision for IQF blueberries. Their specialized technology excels at removing the finest defects in high-volume frozen lines, ensuring top product quality.

Can one machine sort both fresh and frozen fruit?

Yes, the Key Technology VERYX platform provides excellent versatility. A single machine can effectively sort both fresh and frozen products, adapting to different processing seasons.

How difficult is it to integrate these sorters?

Both companies design their sorters for straightforward integration. They feature modular construction and provide support to ensure the machines fit seamlessly into existing processing lines.