Every fry counts, especially when you’re aiming for less waste and more yield. The good news? You don’t need to install an entirely new sorting line to get there. With Optimum Sorting’s smart add-ons, you can transform your existing machine into a true powerhouse. You can, for instance, opt for our S-TEC module for full 360° fry inspection, the M-TEC module for highly accurate metal detection, and advanced software solutions like ‘Sort to Spec’ and ‘Sort to Length’. Each tool is designed to help you get the most out of your raw materials, with less waste and more precision. Looking to level up your French fry machine sorting? This article has everything you need to know.
How 4 smart innovations can redefine French fry machine sorting
Optimum Sorting’s advanced modules, developed through extensive R&D and rigorous testing, bring unmatched precision to your French fry machine sorting process. From smart algorithms to specialized hardware, each component is engineered to enhance throughput, reduce waste, and increase profitability.
These technologies don’t just make fry sorting more efficient, they make it more precise than ever before. Seamlessly integrated into our Novus sorting machine or easily retrofitted to existing systems, many of these solutions are developed in-house and, in some cases, even patented by Optimum Sorting.
1. M-TEC module: advanced metal detection and removal
With the M-TEC module from Optimum Sorting, you take your quality control to the next level. This intelligent detection unit is specifically designed to identify even the tiniest metal fragments (down to just 1 mm) including stainless steel, ferrous, and non-ferrous particles. These contaminants often go unnoticed by cameras and lasers because they’re hidden beneath the product on the belt or embedded within it. M-TEC makes the invisible visible!
The module is built with multiple smaller detection coils, making its sensitivity far superior to that of traditional metal detectors. Thanks to its smart design, the M-TEC module can be seamlessly integrated into your existing sorting machine; a concept that’s truly one-of-a-kind in the market. No extra sorters, no additional steps — just one smooth, continuous inspection cycle. M-TEC delivers the perfect balance: maximum food safety with minimal complexity. It’s efficient, dependable, and can be seamlessly aligned with the way you work.
2. S-TEC Module: enhance your French fry inspection with 360° clarity
In traditional French fry sorting, multiple cameras are typically combined to inspect each fry from every possible angle as it moves along the conveyor. This setup creates an impressive surround view, capturing five out of six sides of your product with remarkable clarity. The only blind spot? The bottom of the fry—hidden against the belt, beyond the reach of any camera. No lens can see through solid surfaces. But that’s where the S-TEC module changes the game…
S-TEC makes it possible to inspect the bottom of each fry, finally completing the full picture. The ‘S’ stands for ‘six’, referring to the sixth side of a cube, which in our case means the bottom of the fry. The S-TEC module features a uniquely patented design, combining high-performance RGB cameras with a rotating ‘stay-clean’ system that ensures crystal-clear imaging at all times.
By inspecting even the bottom of each fry in the finest detail, you dramatically reduce the risk of defects going unnoticed. What was once invisible is now captured with crystal clarity. This added dimension in quality control isn’t a luxury, it’s a gamechanger. In a market where every detail matters, this technology is what separates good from exceptional.
Watch this video to see how Optimum Sorting’s camera technology is used to sort French fries with pinpoint precision:
3. Sort-to-Spec: you set the standards, we sort to match
When it comes to sorting fries, life isn’t always black and white. Sometimes, those little imperfections (like slight discolorations) are perfectly acceptable to the customer. That’s where our intelligent software, ‘Sort-to-Spec’, steps in. This smart tool empowers you to take control, allowing you to define exactly what stays and what goes. Precision meets flexibility, so you can deliver quality that’s not just consistent, but consciously crafted. That way, you reduce the number of fries that would otherwise end up as waste — even though the consumer would have gladly accepted them. It’s a smart and sustainable choice that not only fights food waste, but also helps you get the most out of every single potato. How does it work? It’s surprisingly simple:
- Define what’s acceptable. Decide which imperfections you’re willing to allow in the final product, and how big they can be, for example in square millimetres. Think of small dark spots or tiny bits of potato skin.
- Set your tolerance level. Choose how many fries with these imperfections you’ll accept per batch, expressed in kilograms. This gives you full control over quality without unnecessary waste.
- Let the software take over. Once that limit is reached, the system steps in automatically — sorting out any further deviations with precision and consistency.
4. Sort-to-Length: fine-tune your sorting by length
Just like our Sort-to-Spec technology, Sort-to-Length harnesses the power of advanced image recognition. This time with a sharp focus on length. Every single fry is precisely analyzed, allowing you to define, down to the finest detail, how many short, medium, or long fries make it into your final batch. Fully aligned with your quality standards and your customers’ expectations.
The result? A final product that doesn’t just look more consistent; it feels tailor-made for your market. Whether you’re serving fast food giants, high-end hospitality, or retail shelves, Sort-to-Length helps you deliver exactly what your customers expect, every single time. It’s all about efficiency: you get the most out of every potato, without wasting valuable raw materials. Fries that used to be discarded now get a fair shot, as long as they meet your defined margins. This is sorting reimagined: sharper, smarter, and more sustainable.
Mechanical sorting of fries? Novus gets the job done!
The Novus sorting machine has already proven its worth, especially in potato processing. When it comes to sorting potatoes and fries with pinpoint precision, Novus truly stands out. Its advanced camera technology effortlessly detects deviations in shape and color, delivering impressive accuracy every time. Novus effortlessly removes the following unwanted elements from your product flow:
- Discolored fries, such as those with black or brown spots, or green ends.
- Leftover potato peel, missed during the peeling process.
- Batter balls—small clumps of fried batter that accidentally end up among the fries during production.
- Foreign objects, including pieces of metal, wood, glass, or plastic.
- Fries that fall outside your desired length specifications.
With Novus, nothing slips through the cracks, only quality makes the cut. And that’s not all. Novus is available in a range of widths, up to an impressive 2400 mm, making it the widest optical belt sorter on the market. With this capacity, you can process an exceptionally high volume of fries per hour using just one machine. Combined with its intelligent technologies and robust design, Novus delivers maximum yield and top product quality at a single glance.
Interested in a free demo?
Get in touch with the sales team of Optimum Sorting and have your French fries tested at one of our demo centers around the globe.
Experience firsthand the benefits our machines can bring to your business!
