Optical Grain Sorting with Near-Infrared Spectroscopy
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Solution Overview
Problem
Existing grain sorting techniques, both mechanical and optical, fail to consistently deliver high yields of gluten-free oats due to inadequate removal of gluten-containing foreign grains, leading to contamination levels above the desired 20 ppm limit.
Innovation Solution
Employing near infrared spectroscopy with dual wavelength reflectance data and additional size and shape data in optical sorters, such as Sortex machines, to accurately distinguish oats from contaminants like wheat, barley, and triticale, using InGaAs line scan cameras and visible spectrum cameras to enhance sorting purity and yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mechanical sorting systems are used to separate oats from foreign grains, then the system is simple and cost-effective, but the gluten removal efficiency is insufficient and contamination levels remain high
Solution Approach 1:
The patent replaces mechanical sorting systems with an optical sorting system that uses near-infrared spectroscopy to identify and separate foreign grains from oats. The optical system uses cameras and spectral analysis to detect gluten-containing grains, achieving superior removal efficiency (reducing contamination to below 20 ppm) while maintaining operational simplicity through automated classification and rejection mechanisms.
2Measurement precision
If conventional optical sorters are used to identify foreign grains, then the system can detect grain differences, but the sorting accuracy is insufficient to achieve below 20 ppm gluten levels
Solution Approach 1:
The patent changes the measurement parameter from visible light to near-infrared spectroscopy, operating in the 1100-2200 nm wavelength range. This parameter change enables the detection of spectral characteristics specific to gluten-containing grains, allowing the system to achieve accurate identification and separation that reduces gluten levels to below 20 ppm, meeting the strict gluten-free requirements.
3Productivity
If traditional sorting methods are used to remove foreign grains, then the process is straightforward, but the yield of gluten-free oats is reduced due to high rejection rates of good oats
Solution Approach 1:
The patent implements a feedback mechanism where the optical sorting system continuously analyzes the spectral characteristics of grains in real-time, compares them against reference spectra for oats and foreign grains, and dynamically adjusts the rejection decisions. This feedback loop ensures that only grains with confirmed foreign grain spectral signatures are rejected, minimizing the loss of good oats while maintaining high productivity in the sorting process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Achieves better than 99% rejection of foreign seeds while retaining 97% of good oats, enabling bulk volume processing to produce oats with gluten levels below 10 ppm, thus ensuring compliance with gluten-free labeling standards.
Implementation Method 1
near infrared spectroscopy is employed for identifying the common contaminants (particularly wheat, barley, rye, and triticale). More specifically, the invention partially concerns the preparation of gluten free oats using optical sorters, such as Sortex optical sorters, equipped with near infrared cameras operating in the range of 1100 nm to 2200 nm.
Implementation Method 2
the grain sorting method uses near infrared reflectance data at just two wavelengths to accurately distinguish oats from contaminant grains
Data Source
AI summary
The separation of oats from a combination of grains is performed by obtaining optical data includes both reflectance data and visual data and then analyzing the data in multiple ways, including analyzing information obtained based on ratios of wavelengths and grain imagery. The reflectance data relies on near infrared spectroscopy at requisite ratios of wavelengths in the range of 1100 nm to 2200 nm, while the grain imagery encompasses images of both sides of each of the combination of grains and can also take into account grain size and shape differentiations. The results is an oats separation process wherein at least 99% of foreign grains are rejected with only about 3% of the oats being rejected, while enabling volume processing of grains and establishing a supply of oats with a gluten level well below 20 ppm.