Precision in the Grain Industry: The Tech Revolution in Grain Sorting

Determining the physical characteristics of cereal grains, oilseeds, and soybeans is essential in industrial cereal sorting. With grain as the second-largest traded commodity after oil, precise grading and sorting have a direct impact on food security, safety, and quality worldwide. Once a manual, labor-intensive process, grain sorting has evolved into a highly sophisticated, tech-driven operation that ensures only the highest quality grains reach consumers. From rice and wheat to corn and barley, advanced sorting technologies play a crucial role in the global food supply chain by eliminating contaminants, maximizing efficiency, and meeting growing demands for food safety.

A Rapidly Growing Market

According to Business Research Insights, the global color sorter market reached USD 2.45 billion in 2021 and is expected to exceed USD 4 billion by 2032, with a projected compound annual growth rate (CAGR) of 4.86%. Industry giants such as Bühler, Satake, Key Technology, and GEA Group are propelling this growth with new innovations in optical and AI-based sorting systems, enabling processors to boost both quality and yield.

“The integration of AI with optical and multi-spectral imaging is revolutionizing grain sorting,” shares Andreas Kern, Senior Product Manager at Bühler, one of the key innovators in the sector. “These advancements enhance both the precision and efficiency of sorting, meeting international standards and responding to consumer demands.”

Advanced Technology: From AI to NIR Spectroscopy

Modern grain sorting has embraced technologies once only seen in advanced laboratories. Optical sorting systems now employ high-resolution cameras, lasers, and hyperspectral imaging to sort grains based on size, color, and more subtle characteristics like fungal contamination. For instance, Bühler’s SORTEX H SpectraVision, equipped with AI and hyperspectral imaging, offers high sorting accuracy while reducing food waste.

Similarly, Satake’s FMSR-IR sorter leverages infrared sensors to detect impurities not visible to the human eye. “This technology has been instrumental in enhancing rice quality across over 150 countries,” remarks a Satake spokesperson. These devices are critical in emerging markets, particularly in Africa, where advanced grain sorting is helping countries like Tanzania scale up exports by improving the quality and marketability of staple crops like rice.

AI and Machine Learning: The Next Generation of Grain Sorting

The latest sorting machines use AI and machine learning to improve their performance continuously. With each sorting cycle, algorithms analyze data, enabling machines to enhance sorting precision and throughput. Bühler’s SORTEX J SpectraVision exemplifies this by combining AI with multi-spectral imaging, detecting and removing foreign materials more effectively than ever.

While traditional sorters primarily examine surface properties, Near-Infrared (NIR) technology has allowed companies to assess internal characteristics such as moisture, protein, and contamination levels. The Swedish company BoMill is also at the cutting edge, developing a proprietary technology that analyzes individual grain kernels through near-infrared (NIR) light in transmission mode, allowing precise sorting based on internal qualities like protein and moisture content. According to the company, this technology can handle up to 25,000 kernels per second and has significant implications for reducing food waste and supporting sustainable food production. “Our technology allows processors to classify grains according to internal qualities, contributing to the UN Sustainability Goals by optimizing yield and minimizing waste,” says a BoMill spokesperson.

Portable Solutions for On-Farm Precision

For farmers, quality assessment tools are becoming increasingly accessible. GrainSense’s handheld NIR scanner enables farmers to measure grain protein, moisture, and oil content right in the field, facilitating decisions that improve harvest quality and meet specific market requirements. Such tools are a boon for farmers, particularly those in regions with limited access to larger processing facilities.

X-ray Sorting: Adding Another Layer of Safety

Another technology gaining traction in grain sorting is X-ray imaging, which adds an extra layer of safety by identifying dense contaminants like stones and glass that optical sorters might miss. Multi-spectral imaging, meanwhile, is particularly effective for identifying invisible defects, such as aflatoxin contamination. Research from Cornell University has shown that multi-spectral kernel sorting can significantly reduce aflatoxin levels in maize, addressing a crucial health risk for many African countries affected by mycotoxins. This multi-spectral capability provides an added layer of precision, especially in regions where post-harvest quality is a persistent challenge.​

Africa’s Push for Quality: Reducing Post-Harvest Losses

With post-harvest grain losses reaching as high as 30%, Africa is emerging as a major adopter of advanced grain sorting technology, where agricultural productivity and post-harvest handling have historically presented significant challenges. Bühler’s SORTEX machines and Cimbria’s SEA Chromex are both widely used across the continent, helping to reduce post-harvest losses and meet export quality standards. Kenyan and Nigerian processors, for example, are using Bühler’s technology to minimize wastage and improve the quality of grains for international markets.

Satake, another industry titan, has been pushing the boundaries of grain sorting for decades. The company’s FMSR-IR sorter leverages infrared sensors and multi-spectral imaging to detect impurities invisible to the naked eye. This technology has found widespread use in rice processing, with Satake’s solutions helping processors in over 150 countries improve both quality and throughput​. Recently, the technology was launched in Tanzania to boost rice trade. Anna Mwangamilo, Director of Mechanization and Irrigation in Tanzania’s Ministry of Agriculture, notes, “These technologies enable our farmers to meet export standards, supporting local economies and improving food security.”

In addition to improving food quality, advanced sorting systems support sustainability by reducing food waste. Bühler, for instance, has designed energy-efficient machines that use minimal water, helping processors reduce their environmental footprint. The company is also exploring blockchain integration to provide full traceability from farm to table, which enhances consumer trust and opens new market opportunities for producers focused on transparency.

“With AI and efficient technology, we not only ensure food safety but also support broader sustainability goals,” Bühler’s Kern explains. This focus on sustainability aligns with global efforts to secure food resources for a growing population and a changing climate.

Looking Ahead: Autonomous Sorting as a Transformative Shift in Global Grain Supply

Looking ahead, autonomous sorting systems are poised to revolutionize grain processing further. These systems, powered by real-time data and predictive analytics, will be capable of adjusting to varying quality levels autonomously, reducing downtime and waste. As AI and robotics continue to advance, machines will become increasingly adaptive, learning from each sorting session to enhance accuracy. This will result in fewer false positives and rejected grains, minimizing food waste and improving yields for producers.

The industry’s trajectory highlights the essential role of advanced sorting technologies in the global food supply chain. From supporting sustainable agriculture to enhancing food security, these innovations address both current and future challenges. The future of grain sorting is bright, and with each technological stride, it brings us closer to a world where food quality, safety, and security are attainable for all.

This feature appeared in ISSUE 11 of MILLING MIDDLE EAST & AFRICA MAGAZINE. You can read this and the entire magazine HERE