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.

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Abstract digital lines and wave patterns in blue and black colors.
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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.

Explore WaveSort, our Acoustic Separator
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Black background with blue grid wavy lines on the left and bottom edges.
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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.

    • 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.

sorting machine sorting process

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.

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The Benefits of Using our Automated Sorting Systems

  • Icon of a gear with a wrench in front of it, symbolizing settings or tools.

    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.

  • The image features a speaker icon with a slash through it, alongside the text 'Mute' and a red 'X' symbol.

    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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Resources

  • Vertical pattern of blurred, glowing orange and white circular lights reflecting on dark water at night.

    Read OUr nature paper on High-Speed Acoustic seed Sorting

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    Watch Demonstration Video

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    Download the Seed, Grain & Mineral Sorting Brochure

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.

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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.

sorting machine high speed sorting

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.

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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.

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Abstract digital artwork featuring flowing orange lines on a black background.

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.

  • Icon featuring a central vertical line with two butterfly shapes above and five dots below, all in orange.

    Seeds & Agriculture

    Improve sorting of vegetable seeds, grain, breeding stock, and high-value agricultural products while reducing damage and compressed-air costs.

  • Logo of a blue DNA helix with the text 'Get Your DNA Analysis' on either side.

    Plastics & Circularity

    Enable precise separation of polymers and contaminants while avoiding air turbulence that can reduce sorting consistency.