High-Speed Acoustic Ejection for Optical Sorting
Modern optical sorting systems have evolved rapidly in sensing, machine vision, and AI. Actuation has not.
For decades, industrial sorting machines have relied on compressed air jets and mechanical deflectors to physically separate products after detection. While cameras, hyperspectral sensors, and machine learning models have become increasingly sophisticated, the final sorting decision is still often executed using technology that is noisy, energy-intensive, maintenance-heavy, and fundamentally binary.
The Pneumatic-Free Alternative to Compressed Air Sorting Machines
AcoustoFab replaces compressed air with software-defined acoustic ejection. Using ultrasonic phased arrays, we generate precisely controlled acoustic pressure fields that selectively redirect individual items without physical contact. The result is a solid-state actuator for optical sorting systems that is quieter, more energy efficient, more flexible, and capable of sorting beyond simple accept/reject decisions.
Whether integrated into a new sorting machine or retrofitted into an existing platform, acoustic ejection unlocks a new generation of precision sorting.
The Pneumatic Bottleneck
Compressed air is a hidden cost in every optical sorting machine.
Although pneumatic ejectors and separators are simple and widely deployed, they rely on a chain of compressors, valves, regulators, nozzles, piping, and maintenance infrastructure. The result is significant energy consumption, regular servicing, and inevitable performance degradation over time. In dusty or abrasive environments, nozzles clog. Valves wear. Air leaks develop. Precision deteriorates.
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Binary actuation (accept/reject only)
Limited spatial precision
Mechanical impact on fragile products
Increasing complexity for multi-bin sorting
High energy consumption from compressed air generation
Noise levels that can exceed 80 dB
Wear-prone moving components
As optical inspection systems become more intelligent, the actuator increasingly becomes the limiting factor. This is why plant managers searching for alternatives are not just looking for better cameras—they are looking for a fundamentally better actuator.
How our Technology Improves the Machine Sorting Process
Our sorting machines use ultrasonic phased array transducers to create precise acoustic fields, ejecting, lifting and sorting items into multiple bins. This contact-free approach surpasses traditional methods, offering high-speed, accurate sorting that minimises waste and maximises product quality.
The Benefits of Using our Automated Sorting Systems
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Reduced Wear & Maintenance
Contact-free sorting eliminates mechanical wear, lowering maintenance needs and extending system lifespan.
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Lower Energy Consumption
Acoustic levitation consumes significantly less power than traditional air-jet systems, supporting sustainability goals and reducing energy costs.
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Minimal Waste
Precise control and sorting accuracy lead to less waste, improving resource efficiency and product quality.
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Improved Product Quality
Accurate sorting enhances product quality by ensuring only the best materials are selected.
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Enhanced Sorting Accuracy
Our technology provides unparalleled precision, ensuring high-quality sorting with minimal error rates, ideal for delicate and complex materials.
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Multi-Category Sorting
Move beyond binary sorting. Our multi-category sorter actuator enables up to 5 output bins by modulating acoustic force profiles in real time.
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Throughput
Designed for up to 30 items per second per module, depending on object type, spacing, and system configuration.
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Energy Efficiency
Designed to reduce energy consumption by up to 5× in selected configurations (~0.4 kW/m vs. 1.0+ kW/m for compressed air systems), delivering measurable compressed air energy savings in sorting operations.
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Quiet Operation
Remove 80 dB+ due to loud pneumatic bursts and replace with silent ultrasonic actuation, reducing factory noise and creating a calmer, safer working environment.
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How our Technology Improves the Sorting Process
Our advanced sorting systems enhance the entire process by allowing for non-contact handling and multi-category sorting, adapting easily to different materials and product types. This flexibility reduces downtime, increases throughput, and meets diverse sorting needs with high precision.
Flexible Integration with Existing Infrastructure
AcoustoFab’s modular sorting systems integrate seamlessly with your existing setup, requiring minimal modifications. This adaptability makes it easy to upgrade your processes, adding precision and speed to existing workflows without costly overhauls.
High-Speed Sorting for Maximum Throughput
Designed for high-volume environments, AcoustoFab’s technology achieves rapid sorting speeds without compromising accuracy. By increasing throughput while maintaining quality, our systems meet the demands of fast-paced industries.
Multi-Category Sorting Options for Customised Output
Our sorting systems enable classification into multiple categories, beyond simple binary sorting, for more nuanced and efficient operations. This flexibility supports tailored sorting requirements, optimising results for diverse applications.
Designed for OEM Integration
WaveSort is designed as a drop-in replacement for pneumatic ejectors. Rather than redesigning an entire machine architecture, OEMs can integrate acoustic ejection directly into existing inspection and sorting workflows.
Beyond Seeds: Versatile Industrial Sorting
Although WaveSort was initially developed for seed sorting, the underlying technology is material agnostic.
Any object that can be detected can potentially be redirected using acoustic force.
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Seeds & Agriculture
Improve sorting of vegetable seeds, grain, breeding stock, and high-value agricultural products while reducing damage and compressed-air costs.
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Plastics & Circularity
Enable precise separation of polymers and contaminants while avoiding air turbulence that can reduce sorting consistency.
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Minerals & Mining
Perform selective deflection of particles in dusty environments without nozzle clogging or pneumatic wear.
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Electronics & Advanced Manufacturing
Handle delicate components where mechanical impact, abrasion, or pneumatic shock can introduce defects.
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Research & Specialty Materials
Sort fragile or high-value materials where product preservation is more important than brute-force actuation.
FAQs
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No. While widely deployed in vegetable breeding (tomato, pepper, cucumber), The platform can be adapted for many small solid objects and particles, typically in the millimetre scale, depending on size, density, shape, and presentation. It is currently being applied to plastics recycling and mineral processing where clean, non-contact separation is critical.
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Unlike pneumatic systems that clog or degrade, our platform is fully solid-state. There are no nozzles or valves to fail, making it inherently robust in harsh environments such as grain processing or recycling plants.
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Yes. This is a core advantage. Acoustic force modulation enables reliable sorting into 3–5 bins in a single pass—something compressed air systems cannot achieve consistently.
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No. The system functions as a standard actuator. Force profiles are controlled via software, enabling rapid switching between materials and sorting modes.
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WaveSort uses ultrasonic phased arrays to generate focused acoustic pressure fields. When an object enters the sorting zone, the system creates a targeted acoustic force that redirects the item toward the desired output stream. Unlike compressed air, the force is generated directly by sound and requires no physical contact.
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Yes. The system operates using ultrasound above the range of human hearing. Appropriate shielding, enclosure design, and industrial safety practices are incorporated into deployment configurations.
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WaveSort separates sensing from actuation. Rather than developing another camera system, we focus on replacing the actuator itself. This enables OEMs and operators to retain their existing vision investments while upgrading the most energy-intensive and maintenance-heavy component of the sorting process.
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In some applications, yes. In others, acoustic ejection may initially complement existing sorting architectures before replacing pneumatic systems over time. The optimal deployment depends on product characteristics, machine layout, throughput requirements, and business objectives.
Ready to Eliminate Compressed Air from Your Sorting Line?
Modern optical sorters have become intelligent. Their actuators have not.
WaveSort replaces compressed air with software-defined acoustic ejection, reducing energy consumption, maintenance burden, noise, and infrastructure complexity while enabling new forms of multi-category sorting.
Whether you are building the next generation of sorting machines or upgrading existing installations, AcoustoFab can help bring acoustic ejection into your workflow.
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