SECRETS TO EXTENDING THE LIFESPAN OF COLOR SORTER – OPTIMIZING PERFORMANCE & COSTS

21/08/2025

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Today, color sorters have become an indispensable part of processing lines in agriculture, food, plastics, and minerals. Equipped with AI-based recognition technology, high-resolution cameras, and pneumatic ejectors, color sorters ensure precise product classification, thereby improving output quality and commercial value. However, when operating continuously at high capacity, if not maintained properly, machines can suffer from component wear, reduced efficiency, or unexpected breakdowns.

👉 So how can you keep your color sorter stable, durable, and cost-efficient? Here are 4 golden rules from DTCGroup.

1️⃣ Proper Operator Training

The human factor determines up to 70% of a machine’s lifespan.

Operators must receive formal training from the supplier or technical experts, mastering procedures such as startup, configuration, operation, and cleaning.
More importantly, operators must be able to identify early warning signs: error messages from the camera, inconsistent sorting accuracy, sudden drops in air pressure…
In fact, many factories have reduced 30–40% of annual maintenance costs simply by having a well-trained team that prevents failures before they occur.

DTCGroup always places strong emphasis on training and guiding customers in operating color sorters.

2️⃣ Use the Right Capacity and Function

Every color sorter model is designed with optimal configurations for specific materials: rice, cashew nuts, coffee, pepper, beans, plastic pellets, stones, etc.

Forcing the machine to run over capacity or using it for the wrong purpose (e.g., using a bean sorter for cashew nuts) can easily cause camera errors, reduced accuracy, or component damage.
Recommendation: always consult the technical documentation provided by the manufacturer and strictly follow the machine’s intended functions and operating principles.

3️⃣ Regular Cleaning – Don’t Overlook It!

In agricultural processing environments, fine dust, husks, and impurities are unavoidable.

If not cleaned regularly, dust buildup on cameras, LED lights, and feeding hoppers can distort image recognition and reduce sorting accuracy.
Just a thin dust layer can lower accuracy from 99% down to 94–95%, causing significant product quality loss and reduced value.
Build a routine cleaning schedule: check air filters, wipe cameras and LEDs, vacuum inside the sorting chamber. This takes little time but ensures long-term stable performance.

4️⃣ Scheduled Maintenance – Don’t Delay

Many businesses still follow a “fix it when it breaks” approach – but in reality, this is far more costly than preventive maintenance.

Components such as pneumatic nozzles, air pipes, joints, and valves must be inspected and replaced periodically.
A clogged valve can disrupt the entire pneumatic system, causing hours of downtime.
Proactive scheduled maintenance helps minimize the risk of unexpected shutdowns and ensures 24/7 reliable operation.

Professional warranty and maintenance services by DTCGroup’s experienced engineers.

✅ Good Machines Require Good Practices

With proper operation, cleaning, and maintenance, a color sorter can run stably for many years without replacement, helping businesses save significant costs while maintaining consistent product quality.

👉 At DTCGroup, we don’t just provide the most advanced color sorting machines – we also offer: