AI Intelligent Sorting: KEYETECH's AI Color Sorters for Precision Material Separation

Anhui Keye Intelligent Technology Co., Ltd (KEYETECH) is a national high-tech enterprise founded in 2011 that specializes in the R&D and application of AI technology for industrial and agricultural quality control. The company's core product lines include AI Vision Inspection Equipment and AI Intelligent Sorting machines. With a 29,000 m² factory, a team of approximately 300 employees, and an R&D team of 56 engineers including three PhDs from the University of Science and Technology of China, KEYETECH develops fully self-owned optics, mechanics, electronics, computing, and software technologies.

KEYETECH's AI Intelligent Sorting (color sorter) series covers more than a dozen material types: grains, rice, nuts, pet food, frozen food, traditional Chinese medicinal materials, seasonings, ores, metals, plastics, salt, flower tea, fresh flowers, French fries, vegetables, chicken nuggets, candy, lemon slices, and coffee cherries. Each model is built with carbon steel or stainless steel and shares a common operating envelope: temperature range -20°C to 60°C, air pressure 0.5–0.8 MPa, air consumption 0.6–6 m³/h, and total power 1.2–6.8 kW.

The Problem: Inefficient and Inconsistent Manual Sorting

In industries such as food processing, recycling, and mining, traditional manual sorting is slow, error-prone, and costly. Defects including insect damage, discoloration, foreign materials, and shape anomalies are difficult to detect consistently by human eyes, especially in high-volume batch environments. The global optical sorter market is projected to reach USD 5.79 billion by 2032 (MarketsandMarkets, 2025), reflecting a growing need for automated, AI-driven solutions. In food processing alone, optical sorters generated USD 2.52 billion in 2024, the largest application segment (Grand View Research).

Industry Background: From Color Sorting to AI-Powered Intelligence

Optical sorters have evolved from simple color-based separation to AI-enhanced systems that can identify subtle defects, classify materials by texture or chemical composition, and self-optimize over time. As of 2024, approximately 38% of new industrial belt-line installations incorporate AI-enhanced hyperspectral or NIR modules (EIN Presswire). KEYETECH's machines embed proprietary AI algorithms developed in-house, supported by a dedicated server infrastructure hosting tens of thousands of models. The company's edge computing unit accelerates inference, enabling real-time sorting at high throughput.

KEYETECH's AI Intelligent Sorting Solution

KEYETECH's AI color sorters use a multi-stage process: 1) Material is fed via vibratory feeder onto a belt or chute; 2) Custom-designed industrial cameras capture high-resolution images from multiple angles (top-lighting, side, full-surround); 3) AI algorithms (classification, defect detection, object detection) analyze each particle in milliseconds; 4) Precise air ejectors remove defective or foreign materials. The system operates 24/7 under normal factory conditions and requires only an air compressor and stable power.

All models are offered in two main structural types: channel-type (vertical) and belt-type. Belt-type machines (single-layer or double-layer) are ideal for delicate or irregular-shaped items such as chicken nuggets, lemon slices, and fresh flowers. Channel-type machines are better suited for free-flowing granular products like grains, rice, and seeds.

Step-by-Step Sorting Process

1. Feeding: Material enters the machine via a vibration feeder, ensuring a uniform monolayer stream.
2. Illumination & Imaging: A proprietary optical system (top-lighting or full-surround) illuminates the material. In-house developed cameras capture images at high speed.
3. AI Analysis: The AI server (edge computing unit) runs trained neural network models to classify each item as accept or reject based on defects, color deviations, or shape anomalies.
4. Pneumatic Ejection: High-speed air nozzles fire precisely to remove defective material into a separate reject chute.
5. Output: The accepted product continues to the outlet, while rejects are collected separately. The system can also perform multi-grade sorting by using multiple ejector rows.

Key Use Cases Across Industries

KEYETECH has served over 2,000 clients, including global brands such as Mengniu, Yili, Unilever, Procter & Gamble, Moutai Group, and CATL. The company's AI systems are deployed across food, pharmaceuticals, daily chemicals, textiles, liquor, new energy, electronic components, and tobacco industries.

Comparison of KEYETECH AI Color Sorter Series

Note: Both types are available in carbon steel or stainless steel and operate under the same power/pressure envelope. The choice depends on material characteristics and desired throughput.

Frequently Asked Questions