PET and PVC present a unique challenge in recycling streams due to their similar visual properties but vastly different chemical compositions. To understand why their separation is crucial, we need to examine what happens when these materials mix.

When even small amounts of PVC (as little as 50 parts per million) contaminate PET during the recycling process, several devastating effects occur:

1. The PVC releases hydrochloric acid when heated to PET processing temperatures (around 270°C), causing catalytic degradation of the PET polymer chains.
2. This degradation significantly reduces the intrinsic viscosity of the recycled PET material.
3. The contaminated material exhibits yellowing and increased brittleness.
4. The mechanical properties of the final recycled product become unpredictable and generally inferior.

Beyond these technical issues, PVC contamination can physically damage processing equipment through corrosion from the released hydrochloric acid, leading to costly repairs and downtime.

The Science Behind Optical Sorting

Optical sorting stands as one of the most advanced technologies for automated plastic separation. These systems rely on several key scientific principles:

Near-Infrared (NIR) Spectroscopy

The cornerstone of modern plastic sorting is NIR spectroscopy. This technology exploits the fact that different plastic polymers absorb and reflect infrared light in distinctive patterns based on their molecular structure.

When NIR light hits a plastic flake or bottle:

• The light penetrates slightly below the surface
• Certain wavelengths are absorbed based on the chemical bonds present
• The reflected light creates a unique “spectral fingerprint”
• This fingerprint can identify PET versus PVC with high accuracy

Modern NIR sensors can detect these subtle differences at speeds fast enough to sort thousands of items per minute on a conveyor belt.

X-Ray Transmission Technology

To complement NIR, many advanced systems incorporate X-ray transmission technology. This works especially well for PVC detection because:

• PVC contains chlorine atoms, which absorb X-rays differently than the carbon, hydrogen, and oxygen atoms in PET
• The density difference between PET (1.38 g/cm³) and PVC (1.3-1.45 g/cm³) can be detected through X-ray absorption rates
• Even black-colored PVC, which might confound some optical systems, can be identified through its X-ray signature

RGB Camera Systems

Visual identification also plays a role in modern sorting systems:

• High-resolution cameras capture detailed images of each item
• Advanced image processing algorithms analyze shape, transparency, and color
• Machine learning systems continuously improve identification accuracy
• This method helps identify contaminants that might have similar NIR profiles but different visual characteristics

The Technical Process in Action

To understand how this technology works in practice, let’s follow a mixed stream of PET and PVC materials through MEYER’s sorting system:

1. Material Preparation: The incoming material stream is first prepared through sizing, washing, and drying to optimize detection accuracy.
   
2. Singulation: The mixed plastic pieces are spread onto a high-speed conveyor to ensure individual items can be properly analyzed.
   
3. Multi-Spectral Analysis: As items pass through the detection zone, they are simultaneously scanned by:
   
   • NIR spectrometers operating at multiple wavelength bands
   • X-ray transmission sensors measuring atomic density
   • High-resolution RGB cameras capturing visual characteristics
4. Real-Time Data Fusion: The system cross-references all sensor data, creating a comprehensive material profile for each item in milliseconds.
   
5. Decision Algorithm: The decision engine compares profiles against known signatures for PET and PVC, calculating a confidence score for each classification.
   
6. Precision Ejection: Items identified as PVC are targeted by air jets precisely calibrated to their position, mass, and aerodynamic properties.
   
7. Quality Control: Secondary sensors confirm successful ejection, and the system tracks sorting efficiency metrics in real-time.
   
8. Continuous Calibration: Throughout operation, the system periodically checks against reference materials to maintain calibration and adjust for environmental factors.
   

Overcoming Technical Challenges

MEYER’s systems have had to solve several fundamental technical challenges to achieve reliable PET/PVC separation:

Speed vs. Accuracy Tradeoff

Historically, increasing throughput meant sacrificing identification accuracy. MEYER’s systems overcome this through:

• Custom-designed high-speed NIR sensors with response times under 1 millisecond
• Parallel processing architecture that performs multiple analyses simultaneously
• Optimized conveyor systems that maximize spacing without reducing throughput
• Predictive algorithms that begin analysis before items fully enter the detection zone

Handling Material Variability

Recycled plastic streams present enormous variability in:

• Size and shape of fragments
• Surface contamination affecting readings
• Color additives masking spectral signatures
• Multi-layer materials with different polymer types

MEYER’s systems address these challenges through adaptive detection parameters that automatically adjust sensitivity based on the characteristics of the current material stream.

Environmental Interference

Operating conditions in recycling facilities can introduce various interferences:

• Dust and moisture affecting optical readings
• Temperature fluctuations changing material properties
• Vibration disturbing precise measurements
• Ambient light affecting visual identification

To counter these issues, MEYER’s sorters employ environmental monitoring systems that compensate for changing conditions and sealed optical pathways that prevent contamination of sensitive components.

Economic and Environmental Impact

The implementation of advanced optical sorting for PET/PVC separation delivers substantial benefits:

• Higher Value Recyclate: Properly sorted PET can command premium prices in recycling markets.
• Reduced Processing Costs: Preventing PVC contamination extends equipment life and reduces downtime.
• Increased Recycling Rates: More efficient sorting makes previously uneconomical recycling streams viable.
• Environmental Protection: Proper separation prevents the release of hazardous chlorinated compounds during processing.

Plastic Separation Technology

MEYER continues to advance their sorting technology with several emerging developments:

• Hyperspectral Imaging: Expanding beyond NIR into hundreds of spectral bands for even more precise identification.
• Artificial Intelligence Integration: Deep learning systems that can identify new packaging materials without explicit programming.
• Miniaturization: More compact systems that can be deployed at smaller recycling facilities.
• Tracer Technologies: Working with packaging manufacturers to incorporate harmless tracer compounds that make identification even more reliable.

Conclusion

The technical challenge of separating PET from PVC exemplifies the complexity of modern recycling. Through sophisticated multi-sensor optical sorting technology, MEYER has developed systems capable of identifying and separating these similar-looking but chemically incompatible materials with unprecedented accuracy.

As we move toward a more circular economy, these advanced sorting technologies will play an increasingly vital role in transforming waste streams into valuable resources. The success of PET recycling depends heavily on maintaining material purity, and MEYER’s innovative approach to optical sorting represents a significant step forward in addressing one of recycling’s most persistent technical challenges.

By enabling the efficient removal of PVC contaminants from PET recycling streams, these systems not only improve the economics of plastic recycling but also contribute substantially to environmental sustainability goals.

The post How optical sorters separates PET from PVC: Plastic Cross-Contamination appeared first on Meyer Europe.

In a space filled with machinery, technologies, and innovations, we focus on one thing. Smart, precise sorting solutions that make a real difference in your process and final product quality.

Step in, take a closer look, and let’s talk. Whether you are improving your current setup or planning something new, we’re here to share ideas, experience, and practical solutions tailored to your needs.

Because for us, it’s never just about machines.
It’s about understanding your process and making it better.

March 26–28, 2026
VMU Agriculture Academy, Lithuania
Marguciai stand – Sector D, Booth D19

Come by, meet the team, and see how sorting creates real value.

MEYER. Sorting creates values.

The post Meet MEYER Europe at “Ką pasėsi… 2026” – Let’s Talk about Sorting appeared first on Meyer Europe.

Today is a moment to reflect on how we approach resources. What we often call “waste” still holds value. It simply needs to be recognized, separated, and given a second life. This is where modern technologies play a crucial role. Optical sorting, working quietly in the background of recycling processes, makes it possible to identify materials with precision, improve recovery rates, and ensure higher quality of recycled outputs.

Thanks to continuous advancements in intelligent recognition systems, recycling is becoming more efficient, more accurate, and more scalable than ever before. These innovations support industries in reducing waste, saving resources, and minimizing environmental impact.

On this day, we would like to extend our best wishes to everyone contributing to a more sustainable world. From individuals making conscious choices to companies investing in smarter technologies. Every action matters, and every step forward brings us closer to a cleaner, more efficient future.

Let’s continue working together. Seeing value where others see waste, and building a better tomorrow through smarter recycling.

The post Global Recycling Day: Together for a Greener Tomorrow appeared first on Meyer Europe.

Optical sorting technology utilizes advanced cameras, sensors, and software algorithms to rapidly detect and remove grain imperfections and foreign materials. For Polish grain mills, optical sorting brings numerous advantages:

• Ensuring High-Quality Output: Optical sorters efficiently detect and eliminate contaminants such as defective kernels, small stones, and foreign particles. This guarantees that only superior-quality grains proceed to the milling stage.
  
• Improving Product Consistency: The automation offered by optical sorters ensures consistent grain selection, crucial for the baking industry, which requires uniform flour characteristics for optimal product performance.
  
• Reducing Material Waste: Optical sorting significantly minimizes waste by effectively removing defective grains at an early stage, ensuring only valuable materials are milled.
  

Detailed Comparison: Traditional Sorting vs. Optical Sorting

Traditionally, grain sorting relies heavily on manual or mechanical processes like hand sorting, sieving, and air separation. Although historically effective, these methods present notable limitations:

• Manual Sorting: Highly labor-intensive, manual sorting depends on workers visually inspecting grains, leading to variable outcomes due to human error and fatigue. This process also struggles to identify subtle defects or small contaminants effectively.
  
• Mechanical Sorting: Mechanical sieving and separation often lack precision, resulting in imperfect removal of small impurities and variations in grain size. Additionally, mechanical sorting methods can damage grains, adversely affecting flour quality. Mechanical sorting provides an excellent first step in thoroughly cleaning the seeds. This process helps prepare the material so that optical sorting can achieve the highest possible accuracy and efficiency.
  

Optical sorting, however, effectively addresses these traditional limitations:

• Enhanced Precision: Optical sorters precisely identify even tiny grain defects and contaminants using advanced imaging and sensor technologies.
  
• Greater Efficiency: Capable of sorting large volumes of grain rapidly, optical systems drastically improve throughput compared to manual or mechanical methods.
  
• Operational Cost Reduction: By automating the sorting process, optical technology substantially reduces reliance on manual labor, leading to considerable savings in operational costs.
  

Contaminants and Defects Removed by Optical Sorters

The core value of optical sorting lies in its ability to pinpoint and remove a wide array of problematic elements that decrease the grade and safety of flour. These can be grouped into several categories:

You can read more about mycotoxin control in corn and wheat in this article.

Advantages for Local Grain Mills

The adoption of optical sorting technology yields significant operational improvements, particularly for small and medium-sized Polish mills. Mills utilizing this technology are able to consistently produce higher quality flour, strengthening their competitive advantage. The optical sorting equipment integrates seamlessly with existing milling infrastructure, offering scalable solutions tailored to varying business needs.

Environmental Benefits of Optical Sorting

Polish grain mills adopting optical sorting technology actively contribute to sustainability. By precisely removing defective grains, optical sorting reduces waste and optimizes resource utilization, including energy consumption. This commitment to sustainable practices not only enhances the environmental profile of mills but also aligns with the values of increasingly environmentally aware consumers.

Preparing Polish Mills for Future Challenges

As industry demands evolve, optical sorting technology positions Polish grain mills effectively for future challenges. This innovative technology ensures compliance with stringent regulatory standards and improves overall operational productivity. Investing in optical sorting thus helps mills meet rising customer expectations while remaining agile and competitive.

Summary

Optical sorting technology is a transformative advancement in grain processing, significantly enhancing flour quality, consistency, and efficiency in Polish mills. For mills striving for quality, sustainability, and competitiveness, integrating optical sorting into their processes represents a vital strategic investment.

References

• European Flour Millers Association. (2022). Quality Assurance in Flour Milling.
  
• FAO. (2021). Sustainable practices in grain milling.
  
• Polish Grain and Feed Chamber. (2023). Industry Trends Report.

The post How Polish grain mills improve flour quality with optical sorting appeared first on Meyer Europe.

Start with PET, the transparent, lightweight plastic used for drink bottles, salad tubs, and a surprising amount of polyester clothing. When those items are collected after use, they can be reprocessed into rPET. The term doesn’t describe a different plastic; it describes the same polymer on its second life. You may also see “PCR” (post-consumer recycled) on labels, which simply refers to where the recycled content came from. Most packaging grade rPET is PCR; some streams are PIR (postindustrial), meaning clean production scrap.

How rPET is made, in real life

Picture a bale of used bottles coming off a truck at a sorting facility. Object Sorters pick out PET from the chaos and send it to be shredded into flakes. Those flakes get a deep clean. Labels, glues, and residues are washed off and then they’re run through decontamination steps that strip out anything you don’t want near food. Many recyclers use vacuum decontamination or a process called solid-state polycondensation (SSP) to rebuild polymer chains so the material behaves more like fresh resin. Before the flakes reach the “clean” stage, however, they go through an additional sorting step, already in flake form. At this point, polymer and color sorting systems are used. This allows contaminants to be removed from much smaller fractions that may have gone undetected earlier in the process. In addition, sorting the flakes into different color fractions makes it possible to classify the material for specific end uses, particularly for producing pellets in defined colors. This step plays a key role in determining the final product. Optionally, a UV sorting system can also be installed to separate fluorescent and aged flakes, further supporting the achievement of food grade quality.

The clean flakes are melted and turned into pellets. Converters take those pellets and make new preforms, bottles, thermoformed trays, or sheets. The whole chain works best when the feedstock is clear, consistent, and actually PET.

Mechanical recycling like this is doing the heavy lifting today. Chemical routes, breaking PET back to its building blocks and rebuilding it, are growing, especially for mixed colors and hard to clean streams, but they’re newer and not yet available everywhere.

rPET vs. virgin PET: what changes and what doesn’t

Functionally, rPET can match virgin PET for many packaging and fiber applications. The noticeable difference is often aesthetic: at high recycled percentages you might see a faint tint compared with the very clear look of fresh resin. Additives and careful feedstock selection can reduce that. The environmental side is where rPET generally performs better. It uses less virgin petrochemical material and has a lower overall production footprint when the recycling system runs efficiently. Pricing is not a simple up or down decision. It follows oil markets, bale quality, policy incentives, and demand, which means prices can fluctuate. The key point is to plan for a range rather than a single figure.

Safety, without the marketing gloss

Food grade rPET is not a guess. It’s the outcome of approved processes and testing. In Europe, recyclers seek EFSA opinions for their decontamination steps; in the U.S., the FDA issues letters of no objection for systems that meet its criteria. Finished packaging still needs migration testing under the conditions you’ll actually use:time, temperature, and the type of food or drink matter. If you’re buying, ask for the paperwork up front: regulatory status, process controls, and test reports tied to your application.

Design so it can be recycled again

Recyclability isn’t just about the base resin. Mono material PET bottles and trays are easier to sort and reprocess at quality. Labels that wash off cleanly help. Hard to remove labels can interfere with the sorting process at the object sorting stage. However, modern AI and Deep Learning systems can effectively handle this by recognizing and classifying specific types of bottles despite the presence of labels. Labels can also be removed later in the process, for example during flotation or by using systems designed to separate the lightest fractions. Clear or light blue PET yields the most versatile rPET; heavy tints limit what the next life can be. Standard polyolefin closures require a proper approach as well. They can be removed earlier in the process before further treatment, or separated later, in flake stage, during polymer sorting, or during color sorting (based on differences in flake transparency).

Where rPET shows up

You can find rPET in drink bottles, food containers, shampoo and cleaning bottles, and in many textiles like fleece, tote bags, and carpets.Films, straps, and even 3D printing filament use it too. In short: it’s common, and it is becoming more important as recycled content rules become stricter.

The practical challenges

Supply and quality are the constant tension. Food grade bales are in demand, and clear bottle feedstock commands a premium. Mixed colors or contamination push material toward lower value outlets and make it harder to hit high recycled content in transparent packaging. There’s also polymer “fatigue”: each heat history shortens chains a bit, which is why processes like SSP matter to restore intrinsic viscosity. In addition to SSP, UV sorting allows for the removal of degraded flakes. This makes it possible to improve material quality earlier in the process, which directly translates into better quality of the pellets. None of these issues are dealbreakers, but they’re the reasons serious buyers lock in supply, set realistic specs, and test on their own lines early.

Buying rPET without the headaches

If you’re sourcing rPET for packaging, treat it like any other critical input. Specify recycled content by mass and be clear that you mean PCR if that’s the goalDefine the optical and mechanical targets that are most relevant to your product, such as clarity and haze, Lab color, intrinsic viscosity for bottles, top load or impact strength, and sealability for trays.Ask for chain of custody documentation such as GRS or RCS if you plan to make public claims. Get the compliance evidence for your exact conditions of use, not a generic data sheet. Then run trials. Preform design, wall thickness, label and sleeve behavior, and line speeds will tell you more in a week than a dozen meetings.

What about textiles?

rPET fibers are, essentially, polyester made from bottle grade PET. The climate benefit depends on the feedstock and the system you’re comparing against, but the appeal is straightforward: less virgin polymer. If you’ll communicate about it, traceability matters. Use recognized standards and be careful with “ocean plastic” language unless it’s truly, verifiably sourced that way. Microfibre shedding is a real issue; fabric construction and care instructions (cooler washes, gentler cycles) help reduce it.

Quick answers to common questions

1. Is rPET safe for food and drinks? Yes—when it’s produced with an approved process and the final packaging passes migration tests for your specific use.
   
2. Can PET be recycled over and over? It can go through multiple mechanical cycles before properties drift; chemical recycling can reset it back to monomers.
   
3. Can rPET bottles be crystal clear? Often, yes. With high quality feedstock and the right additives, clarity comes very close to virgin.

rPET is not a silver bullet, but it is a practical and scalable way to reduce virgin plastic in products people use every day. Design for it, source it with open eyes, and it will steadily reduce your footprint and strengthen your story without requiring consumers to change much at all.

The post rPET: The recycled plastic most of us touch without noticing appeared first on Meyer Europe.

The basics of glass recycling – what does it really look like?

Glass can be recycled endlessly when handled correctly. Many people ask how glass is sorted, and the answer depends on the stage of production. At home, your job is organization. In professional plants, enormous volumes travel through conveyors, screens, and innovative optical sorting solutions (like sorters), reading thousands of particles per second. 

In Europe, the overall collection rate for glass packaging reaches around 80.8%, showing how well-structured systems improve material recovery when the stream is clean and consistent.

At MEYER, we have optical systems supporting these processes, yet the foundation still begins with the material you sort on your end. Good initial habits lead to cleaner output in the long run.

Remember!

Glass recycling fosters a circular system, supported by informed decision-making at every stage. Once you grasp the basics, the workflow becomes surprisingly logical.

How to prepare glass before sorting?

Before technology enters the picture, you start with preparation, and this early stage is directly connected to the processes used in modern facilities based on glass sorting. Clean glass makes life easier for recycling facilities. Light rinsing helps. Removing caps, loose rings, or leftover food clears the path for cameras downstream.

Even advanced lines benefit from your simple steps. In plants using optical equipment, operators often say that well-prepared input increases efficiency. MEYER equipment works best with reliable streams, and preparation helps maintain that reliability.

How to sort glass for recycling? 4 rules that matter!

When learning how to sort glass for recycling, it helps to follow a short and simple set of principles, especially when facilities use detection toolslike Optical Sorters. These actions create the structure that the professional line needs to deliver refined cullet.

What do we mean?

• separate clear, brown, and green streams, giving facilities consistent material;
• remove caps, rings, and labels whenever you can, reducing noise for scanners;
• keep stones, ceramics, mirrors, and heat-treated cookware away from glass streams, because they disrupt melting processes;
• pack broken glass being sorted in a secure bag when moving it to a drop-off location.

Common contaminants in glass recycling and why they matter?

How do advanced systems handle sorting in industrial facilities?

Once your part ends, industrial plants take over. This is where a glass sorting machine becomes essential. These machines combine specialized cameras, structured lighting, and fast ejectors to classify every particle.

Optical sorting technology works at high speed. Cameras capture details you never notice with the naked eye. At MEYER, we have imaging modules capable of reading subtle differences in shade or texture, helping plants achieve the desired output. Deep-learning software supports these cameras by reading consistent patterns in the stream.

Industrial sorting typically involves several stages. The first pass separates colors.  The next stages allow for obtaining the cleanest possible material flow and transparent, uniformly colored fractions. The goal is steady and highly predictable cullet ready for remelting.

What happens to broken glass being sorted?

You rarely see whole bottles inside a recycling plant. The majority arrives already broken. Plants treat this as usual. Broken glass being sorted runs across vibrating decks, separating it by size. Smaller fragments fall through first while larger ones move forward.

Once sized, optical systems scan every particle. Cameras detect color and micro-details. Ejectors remove off-color pieces instantly. At MEYER’s Test Center, operators often show how small changes in tint influence classification. Watching it in action highlights how precise these systems have become.

Remember!

Broken material works perfectly in recycling as long as it’s clean, separated, and free from contaminants.

How does plastic get sorted from glass?

People often ask: How does plastic get sorted from glass? The answer stems from optical behavior, and many of the ideas behind this process are reflected in EU food safety standards, particularly in the context of optical sorting, as explained in our blog post.

Glass interacts with light differently from plastic, and plastics present their own range of density levels, textures, and transparency profiles. Machines read these distinctions instantly. AI models interpret edge structure and brightness, supporting fast and reliable separation on industrial lines. 

“At MEYER, we have systems capable of recognizing shape and color variations, delivering stable performance even when material streams change. Some plants use density tables for additional refinement, creating well-organized flows that help keep each material in its dedicated cycle.” – MEYER Europe Technical Team.

Step-by-step workflow inside a modern glass sorting facility

A clear view of the step-by-step workflow becomes easier when you relate the entire process to insights discussed in the role of optical sorters, offering a broader perspective on how modern detection supports material recovery.

1. Delivery

Trucks unload material into receiving bays. Operators examine the batch.

2. Pre-cleaning

Machines remove papers, loose labels, and lightweight debris.

3. Screening

Screens separate materials by size to help with later detection.

4. Color sorting

An optical line separates green, brown, and clear cullet. A glass sorting machine rapidly reads each fragment.

5. Density refinement

Some plants use density-based methods to remove stones or ceramics.

6. Final polishing

A final optical pass clears remaining defects. MEYER equipment supports multi-stage workflows for plants needing high purity.

7. Storage

Clean cullet is moved into silos and later transported to furnaces.

The impact of AI and automation

AI reshapes how plants interpret material streams, and whenever you need guidance or want to begin planning improvements for your facility, just contact us to start the process. Instead of relying on fixed parameters, intelligent systems learn patterns over time, supporting adaptive behavior when streams shift or when batches vary.

At MEYER, we utilize AI tools that analyze shapes, textures, and colors with high precision. This increases stability for extensive facilities managing heavy flows. Automation also reduces labor pressure and improves consistency across shifts.

As recycling grows across Europe, AI becomes an essential part of the long-term strategy for material recovery. 

References:

1. https://www.recovery-worldwide.com/en/artikel/glass-recycling-current-market-trends-3248774.html
2. https://www.acrplus.org/en/news/european-glass-packaging-recycling-reached-80-8-in-2023-4967
3. https://www.recycledmaterials.org/
4. https://www.sciencedirect.com/journal/waste-management

The post How to sort glass for recycling? 4 essential rules! appeared first on Meyer Europe.

Fusarium head blight is a fungal disease affecting wheat and other small grains. It commonly occurs in wet, humid conditions around flowering time. The infection is caused by Fusarium species (such as F. graminearum or F. culmorum) that invade the developing wheat heads. Infected wheat kernels often become shriveled, lightweight, and discolored, taking on a chalky white or pinkish appearance due to the fungal growth. These visibly affected grains are referred to as Fusarium-damaged kernels (FDK), or “scabby” kernels in the U.S. Such kernels typically have lower weight and poor milling quality.

Examples of Fusarium-damaged wheat kernels (right) compared to healthy kernels (left). Infected kernels tend to be shriveled, chalky white or pinkish, with fibrous fungal growth, whereas healthy kernels are plump and uniformly colored.

A major concern with Fusarium infection is the production of mycotoxins. As the fungus grows on the grain, it produces toxic compounds – most notably deoxynivalenol (DON), commonly called vomitoxin. DON and related toxins accumulate in the grain during infection. Consuming grain with high DON levels is harmful to humans and animals, causing symptoms like nausea, vomiting, and other gastrointestinal distress. For this reason, strict regulatory or advisory limits on DON are in place in many countries to protect food and feed safety. Processors must keep DON levels low, and grain shipments with too many Fusarium-infected kernels or excessive toxin levels can be downgraded or rejected. In short, Fusarium contamination not only reduces crop yield in the field but also threatens the safety, quality, and marketability of wheat in the supply chain.

Why fusarium contamination is a problem

Fusarium infection impacts the wheat supply in several ways:

• Health Risks: Fusarium fungi produce DON and other toxins (like zearalenone) that pose risks to food and feed. Eating products made from contaminated wheat can cause acute illness in people and livestock. Even at lower doses, these toxins may reduce livestock performance (for example, pigs may eat less feed if it contains DON). Ensuring these mycotoxins are kept out of the food chain is paramount for public health.
  
• Quality and Yield Loss: Infected kernels are often damaged and lightweight, leading to lower flour yield and baking quality. A high percentage of FDK in harvested grain means less saleable product – FHB outbreaks can significantly cut yields and test weights. The milling process is also less efficient with diseased kernels, and flour color or functionality may be affected by their presence.
  
• Economic Impact: Most grain buyers and food processors have strict limits on FDK and DON. For example, only a small percentage of Fusarium-damaged kernels is tolerated in wheat intended for human food. If a load exceeds those limits, its grade is lowered or it may be rejected entirely, costing the supplier money and logistics delays. Likewise, processors face costly recalls or regulatory actions if a contaminated product reaches consumers. Thus, there is strong economic incentive to detect and remove Fusarium-infected wheat early in processing.
  

In summary, Fusarium contamination is both a food safety issue and a quality issue. It demands effective control measures from farm to mill to prevent tainted grain from entering food products.

Limitations of traditional detection methods

Identifying and removing Fusarium-infected kernels has historically been challenging. Traditional methods include visual inspection and basic mechanical cleaning, but these approaches have significant limitations:

• Visual Grading and Hand Sorting: Grain inspectors often visually examine a sample of wheat for FDK – looking for the telltale chalky or pinkish, shrunken kernels. While this can give an estimate of Fusarium presence, it’s labor-intensive and subjective. Manually picking out scabby kernels from large quantities of grain is impractical. In fact, visual sorting is prone to human error and inconsistency; different inspectors may not agree, and fatigue can cause mistakes. Small or mildly infected kernels might be overlooked, especially when thousands of kernels are passing by each minute.
  
• Laboratory Testing: To detect mycotoxins like DON, processors rely on lab tests (e.g. rapid test kits or chromatography) on grain samples. While lab testing accurately measures toxin levels, it’s slow and performed on only a small sample of the lot. There is a risk that hotspots of contamination go undetected if they weren’t in the tested sample. Moreover, testing doesn’t physically remove the bad kernels; it only informs whether a lot is over the limit. At that point, the grain may already be in the supply chain, and blending or cleaning becomes necessary to salvage it.
  
• Mechanical Cleaning Equipment: Standard cleaning equipment in mills (such as sieves, aspirators, and gravity tables) can remove some Fusarium-damaged kernels indirectly. Heavily infected kernels are often smaller, lighter, or more shriveled, so gravity separators and aspirators will kick out some of these low-density kernels. However, these machines are not foolproof Fusarium detectors – some infected kernels have size/weight similar to healthy grain and will slip through. Conversely, some good kernels may be discarded in the attempt to remove bad ones, leading to product loss. Mechanical methods also cannot “see” the actual fungal infection or toxin; they only segregate by physical properties, which is an imperfect proxy.
  

Given these limitations, it’s clear that relying on traditional sorting and testing may leave processors vulnerable to contaminated kernels ending up in flour or other end products. What’s needed is a faster, more precise way to spot and eliminate Fusarium-infected grain in the processing line. This is where modern optical sorting comes in.

MEYER Optical Sorters: A leading solution for Fusarium control

When it comes to optical sorting in the food industry, MEYER is a name that stands out as an innovator. MEYER’s optical sorting machines are widely used in grain processing for their accuracy, efficiency, and advanced features tailored to food safety challenges like Fusarium contamination. Below, we highlight how MEYER optical sorters specifically help prevent Fusarium-infected wheat from entering the food supply:

• Multi-Sensor Inspection: MEYER optical sorters leverage a combination of full-color cameras and multispectral system to scrutinize each grain. The high-resolution cameras capture fine color details, easily spotting kernels with the off-color hues or whitened appearance caused by Fusarium infection. In addition, MEYER offers models equipped with infrared (IR) cameras and even ultraviolet detection, forming a multispectral system that can detect defects beyond the visible spectrum. This means a MEYER sorter can pick up on hidden fungal presence or “invisible” damage inside a kernel, which pure optical (visible-light) systems might miss. The integrated vision system in MEYER machines can evaluate color, shape, density, and texture simultaneously, allowing for precise identification of Fusarium-damaged kernels from multiple angles.
  
• AI-Powered Recognition: A standout feature of MEYER’s technology is the use of artificial intelligence (AI) and deep learning algorithms in sorting. Instead of relying only on static pre-set thresholds, MEYER sorters are equipped with AI that has been trained on vast libraries of grain images. The system “learns” the subtle patterns that distinguish a slightly Fusarium-infected kernel from a healthy one – such as slight wrinkling, a touch of pink near the germ, or a certain shape profile. This AI-driven approach leads to extremely high classification accuracy, even for very small or early-stage defects. According to MEYER, their AI system can identify defects on the scale of a single pixel difference in an image. In practical terms, MEYER optical sorters can more reliably detect Fusarium-contaminated kernels while minimizing false rejects (good kernels thrown out by mistake). This intelligent sorting reduces waste and ensures you’re only removing kernels that truly need removal.
  
• Effective Mold and Toxin Removal: MEYER’s machines have proven effective at rejecting moldy and discolored kernels from grain. For instance, the MEYER CG series chute sorter is capable of effectively rejecting moldy, discolored, broken, and other impurities. In the context of Fusarium, this means the sorter will target the visual mold signs (whitish or pink fuzz on the kernel) and the discoloration associated with scab. By kicking out these kernels, a MEYER sorter substantially reduces the Fusarium load. Industry usage and case studies report that installing optical sorters upstream in the milling process leads to flour with significantly lower DON levels, because the source of the toxin (the infected kernels) has been largely removed ahead of time. This preventative removal is far more efficient than trying to blend or dilute contaminated grain after the fact.
  
• High Throughput & Precision Ejection: In industrial grain processing, speed matters. MEYER optical sorters are designed for high throughput – certain models can process several tons of wheat per hour while maintaining meticulous inspection of each kernel. For example, even a compact MEYER sorter (M2 model) can handle up to ~2 tons/hour with over 99.9% sorting accuracy in separating good vs. defective kernels. Critical to this performance are MEYER’s patented Maglev Ejectors®, which are ultra-fast, contact-free air valves that remove bad kernels with pinpoint precision. These ejectors operate at up to 1200 ejections per second, opening and closing in milliseconds. The benefit is twofold: even at high belt speeds, no contaminated kernel escapes the detector without being expelled, and the ejectors are so precise that very few good kernels get accidentally removed. This efficiency means processors don’t have to sacrifice large volumes of product to achieve safety – MEYER sorters minimize good grain loss while maximizing contaminant removal.
  
• Customizable and User-Friendly: MEYER understands that every processing plant has unique needs. Their optical sorters come with flexible settings and programs that can be tailored to the degree of Fusarium challenge. Operators can adjust sensitivity, define what level of discoloration triggers rejection, and even save multiple sorting modes for different wheat varieties or conditions. Despite the advanced technology under the hood, MEYER machines feature a simplified, intuitive interface for operators. This makes it practical for food industry staff to monitor and tweak the sorting process without specialized technical training. Remote monitoring and diagnostics are also available, meaning MEYER’s support team can assist with tuning the machine to target Fusarium if needed, or troubleshoot issues quickly to minimize downtime.
  

In combination, these features make MEYER optical sorters a leading solution for Fusarium contamination control. They bring together sensor technology and intelligent software to achieve what manual methods simply can’t – near-flawless removal of infected kernels at industrial scale. The table below summarizes some key features and how they specifically help in detecting Fusarium-infected wheat:

Features of modern optical sorters for Fusarium detection

Conclusion

Fusarium contamination in wheat is a persistent challenge for the food processing industry – it threatens food safety, reduces grain quality, and can lead to significant economic losses. Traditional methods of detecting or removing Fusarium-infected kernels have often fallen short, but modern optical sorting technology offers a robust solution. By using high-tech cameras and intelligent algorithms, optical sorters can identify and eliminate Fusarium-damaged kernels with unprecedented precision, helping to protect consumers from harmful mycotoxins like DON and preserving the quality of wheat-based products.

MEYER’s optical sorters exemplify the capabilities now available to millers and grain processors. With multi-spectral cameras, AI-driven defect recognition, and ultra-fast rejection systems, MEYER machines are able to dramatically reduce Fusarium contamination in processed wheat – all while maintaining high throughput and yield of good product. Processors that implement such optical sorting systems gain an important layer of protection: they can confidently deliver flour and other wheat products that meet stringent safety standards and quality specs.

Investing in optical sorting is increasingly becoming standard practice in the grain industry’s fight against mycotoxins. It acts as a critical CCP (Critical Control Point) in food safety plans, removing contaminants before they end up in final food products. In short, advanced optical sorters like MEYER’s help ensure that the wheat that goes into our breads, pastas, and cereals is clean, safe, and Fusarium-free. This technology not only safeguards public health but also gives food industry professionals peace of mind and a competitive edge in delivering high-quality, safe products to the market.

References

1. Canadian Grain Commission – Identifying wheat and barley seed affected by Fusarium head blight grainscanada.gc.cagrainscanada.gc.ca. (Describes Fusarium head blight, Fusarium-damaged kernels, mycotoxin production, and economic impacts.)
   
2. Wegulo, S.N. & Dowell, F.E. (2008). Near-infrared versus visual sorting of Fusarium-damaged kernels in winter wheat. Can. J. Plant Sci. 88:1087–1089 ars.usda.govars.usda.gov. (Notes that FHB causes shriveled/discolored kernels, reduces yield and quality, produces mycotoxins like DON and zearalenone, and discusses limitations of visual sorting vs NIR sorting.)
   
3. Carmack, W.J. et al. (2020). Optical sorter-based selection effectively identifies Fusarium head blight resistance in wheat. Front. Plant Sci. 11:1318 frontiersin.orgfrontiersin.org. (Reports that optical sorting was effective at reducing DON toxin and Fusarium-damaged kernels, and details DON’s harmful effects on humans/animals.)

The post Fusarium Contamination in Wheat: Risks and Optical Sorting Solutions appeared first on Meyer Europe.

Stop by to watch MEYER machine in action, ask questions, exchange experiences and talk with people who work with sorting solutions every day.

• Stand: G21D
• Date: January 21 to 24, 2026
• Place: Hungexpo Budapest Congress and Exhibition Centre

We look forward to meeting you

Sorting Creates Values

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Optical sorters rely on precise detection technologies—including color cameras, NIR sensors, and hyperspectral imaging—to identify and separate materials. Contaminated or poorly prepared feedstock can lead to:

• Reduced sorting accuracy and product quality
• Increased false positives and negatives
• Premature wear of sorting equipment components
• Higher maintenance costs and downtime
• Compromised performance due to dust and debris
• a larger amount of rejected material in the sorting process

Essential steps for material pre-cleaning

1. Remove large contaminants and foreign objects

Begin by eliminating oversized items, metals, and obvious contaminants that could damage downstream equipment:

• Screen out oversized materials using vibrating screens or trommels
• Extract ferrous metals with magnetic separators positioned early in the process
• Remove non-ferrous metals using eddy current separators when applicable
• Hand-pick large foreign objects that automated systems might miss
• Implement an object sorter that will handle the preliminary separation of the material.

2. Size classification and homogenization

Consistent particle size improves optical sorting performance significantly:

• Implement multi-deck screening to create uniform size fractions
• Target optimal size ranges for your specific optical sorter (typically 3-10mm for most applications)
• Consider material density when determining appropriate sizing equipment
• Maintain consistent feed rates to prevent overloading sorting systems
• Introduce mixing silos to homogenize the material fractions fed into the sorter’s hopper.

3. Dust and fine particle removal

Dust accumulation on optical sensors reduces detection accuracy and requires frequent cleaning:

• Install dust extraction systems at key transfer points
• Use air classification to remove lightweight contaminants and fines
• Implement cyclone separators for effective dust collection
• Consider water washing for applications where moisture is acceptable
• Select sorters equipped with additional dust removal systems, such as the MEYER Upper Dust Sucking System.

4. Surface cleaning for enhanced detection

Clean material surfaces allow optical sensors to properly identify material characteristics:

• Remove labels and adhesives from plastic containers when possible
• Clean organic residues that may interfere with NIR detection
• Address surface oxidation on metals that could affect color sorting
• Consider friction washing for materials requiring more intensive cleaning

Below you can see comparison of different cleaning methods with its typical use cases:

Sample preparation for testing and calibration

Creating representative test samples

When preparing samples for optical sorter testing or calibration:

• Prepare a sample representative of the types of material your company processes.
• Maintain original contamination levels during initial testing phases
• Document sample preparation methods for consistent reproduction
• Prepare sufficient quantities for comprehensive testing (minimum 20-60kg recommended)

Sample conditioning protocol

1. Visual inspection and documentation of sample composition
2. Pre-sorting into major categories to understand baseline material mix
3. Final mixing to ensure homogeneous distribution
4. Prepare separate samples of contaminations typical for your material

Material-specific preparation guidelines

Plastic waste processing

• Address PET bottle label removal for high-purity applications
• Consider density separation for mixed plastic streams
• Implement hot washing for heavily contaminated materials
• Adding preliminary object separation at the start of the production line.

Food product sorting

• Maintain cold chain requirements during preparation
• Remove excess moisture that could affect optical detection
• Size grade to eliminate broken pieces and fragments
• Ensure food safety protocols throughout the process

Electronic waste (e-waste) preparation

• Complete safe dismantling and component separation
• Remove batteries and hazardous materials first
• Liberation of target materials through controlled shredding
• Dust suppression and worker safety measures

Material-specific preparation requirements

Quality control and monitoring

Establishing preparation standards

• Document standard operating procedures for each material type
• Implement quality checkpoints at critical preparation stages
• Monitor key parameters such as moisture content, size distribution, and contamination levels
• Regular calibration of preparation equipment

Performance tracking

Track preparation effectiveness through:

• Sorting efficiency measurements comparing prepared vs. unprepared materials
• Equipment utilization rates and maintenance frequency
• Final product quality metrics and customer feedback
• Cost-benefit analysis of preparation investments

Common preparation mistakes to avoid

• Over-cleaning materials beyond what’s necessary for effective sorting
• Inadequate size control leading to inconsistent feed presentation
• Insufficient dust removal causing sensor contamination
• Poor sample representation during testing phases
• Neglecting equipment calibration after preparation system changes

Optimizing your preparation process

Continuous improvement strategies

• Regular process audits to identify bottlenecks and inefficiencies
• Technology upgrades in preparation equipment as needed
• Staff training on proper preparation techniques
• Data collection and analysis to drive process improvements

Integration with sorting operations

• Synchronize preparation capacity with sorting line throughput
• Implement buffer storage to manage material flow variations
• Coordinate maintenance schedules across preparation and sorting equipment
• Establish clear communication protocols between preparation and sorting operators

Conclusion

Effective preliminary material cleaning is not just a preprocessing step—it’s a critical investment in your optical sorting operation’s success. By implementing thorough preparation protocols, monitoring key quality parameters, and continuously improving your processes, you’ll achieve higher sorting efficiency, better product quality, and reduced operational costs.

Remember that material preparation requirements vary significantly based on input material characteristics, target product specifications, and optical sorting technology. Work closely with your equipment suppliers and process engineers to develop preparation protocols optimized for your specific application.

The time and resources invested in proper material preparation will pay dividends through improved sorting performance, reduced maintenance requirements, and higher-quality end products that meet increasingly stringent market demands.

Frequently Asked Questions (FAQ)

Why is pre-cleaning important in optical sorting?
Because optical sorters rely on clean surfaces and consistent particle size to detect materials accurately. Skipping preparation leads to errors, downtime, and higher maintenance costs.

What is the best way to prepare PET bottles?
Remove caps and closures, strip labels, and consider hot washing for sticky residues. For high-purity rPET applications, density separation adds extra quality assurance.

How clean should materials be before entering an optical sorter?
Not spotless, but free from dust, oversized contaminants, and major surface residues. The goal is to ensure sensors can clearly identify each item’s material signature.

Can I over-clean materials?
Yes—over-cleaning wastes resources and may not improve sorting results. The focus should be on achieving consistent size, dust reduction, and visible surface clarity.

Does material preparation differ by industry?
Absolutely. Food requires strict hygiene and size grading, plastics often need label removal, while e-waste demands hazardous component removal first.

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