Written by Peter Denhard, Business Development Manager
Written by Peter Denhard, Business Development Manager
In today's evolving global market, food processors face the complex balancing act of sustainability and growth. Sometimes, when one goes up, the other goes down. With tightening environmental regulations, heightened consumer demand for eco-friendly products, and the rising cost of resources, finding ways to optimize quality and efficiency become paramount.
At Bühler SORTEX, we undertook a study to show that refurbishing an optical sorter’s ejectors hit multiple success markers, from reducing air usage by up to 60%, to increasing yield and quality.
Ejectors: The Unseen Workhorse
Ejectors are the precision instruments of an optical sorter, responsible for accurately removing defective products. However, over time and billions of cycles—approximately 2 billion for small dry products and 1 billion for wet or frozen products— ejector wear is inevitable. This degradation directly impacts performance, resulting in lower accept rates as the sorter begins to reject a higher percentage of good product. Ultimately, this can compromise product quality and increase operational costs due to wasted compressed air and the over-ejection of good product.
Quantifying the Impact: Insights from a New Study
To quantify the impact of ejector refurbishment, we conducted a study examining various ejector conditions: New, Worn, and Refurbished. The results were compelling. Our study demonstrated that both new and refurbished ejectors exhibited no air leakage, eliminating a major source of wasted energy.
In stark contrast, "Worn" ejectors showed considerable air wastage. Furthermore, while refurbished ejectors maintained an optimal flow rate, "Worn" ejectors were found to consume more than double the air compared to new units. This excess consumption not only drives up energy bills but also leads to over-ejection of good product, generating unnecessary waste.
When it came to sort quality, the study showed that higher ON-flow (energy consumption during sorting) resulted in higher yield. Both new and refurbished ejectors proved to be significantly more precise. This precision reduces the costs of over-ejecting good product and ensures optimal yield.
The study highlights that refurbished ejectors deliver performance remarkably close to that of brand-new sorters.
This means investing in ejector refurbishment isn't just about maintenance; it's about re-unlocking a machine's full potential.
Total Care: Your Partner in Unlocking Optimal Results
Ejector refurbishment is a cornerstone of our comprehensive Total Care service, offering tailored solutions, from in-depth machine analysis and part monitoring to proactive maintenance and repair. Whether through on-site engineer support or trusted remote consultation, we are available when you need us. By partnering with Bühler SORTEX Total Care, you protect your investment, reduce operational costs through maximized uptime, and ensure reliable success in your process.
Ready to revitalize your optical sorter and achieve a boost in performance and sustainability? Contact Bühler SORTEX today to learn more about ejector refurbishment and Total Care.
