Optical sorting offers a return on investment

More seed potatoes of the right size = immediate additional yield

The financial benefit of optical sorting starts with greater accuracy in size separation. Optical size sorters assess each potato individually based on multiple camera images. They look not only at diameter, but also at length, volume and shape. This results in a much cleaner separation than with mechanical sorting.

Tests show that the Optica CS optical size sorter sorts up to 25% more accurately than mechanical shaking or impact sorters, particularly with elongated varieties such as Spunta and Agria. In practice, this means that significantly fewer seed potatoes are incorrectly classified as oversized or in other lower-value grades. Particularly in the current season, where oversized potatoes represent little value, this provides a clear financial benefit.

Every extra percentage point of seed potatoes in the right size matters. With larger volumes, an improvement of just a few percentage points can quickly add up to tens of tonnes of extra saleable seed potatoes in the desired size category.

Less misclassification into smaller sizes

After all, mechanical sorters operate with fixed mesh sizes and are therefore more susceptible to shape variations. Elongated potatoes ‘bounce’ over the sorting screens and thus end up in the wrong bin or crate. Optical sorting prevents this misclassification and ensures that potatoes are sorted into the correct size.

Thanks to the higher accuracy, more product is retained in the standard planting sizes. This reduces the proportion of oversized potatoes and increases the average yield per tonne. Optical sorting thus acts as a yield booster: not by growing more, but by making better use of what is already there.

Calculation example: benefit per hectare

The financial benefit of more accurate optical sorting can also be clearly demonstrated on a per-hectare basis. Take as a starting point a plot of seed potatoes where, after sorting, 10 tonnes per hectare end up in the oversized category. Suppose that in the current season, the oversized potatoes yield perhaps only €0.025 per kilo on average, whilst seed potatoes in the standard sizes are worth around €0.25 per kilo.

If optical sorting with the Optica CS ensures that 20% of this oversized crop is correctly classified into the seed potato size, this amounts to 2,000 kg per hectare being diverted to a different use. In this example, the price difference is €0.225 per kilo. This results in an additional yield of: 2,000 kg × €0.225 = €450 per hectare.

And this difference arises purely from more accurate sorting, without any additional cultivation costs. At farm level, with substantial areas of seed potatoes, this benefit quickly adds up to tens of thousands of euros. Particularly in years when the oversized portion has little value, this calculation demonstrates just how significant the impact of optical sorting can be on the final balance.

Labour savings with measurable results

In addition to improved size separation, optical sorting also delivers significant savings in labour costs. Optical quality sorters such as the Optica Q automatically detect diseases, defects, clods and shape abnormalities. Manual re-checking is greatly reduced or even rendered unnecessary.

Fewer people on the sorting line means lower labour costs and reduced reliance on scarce labour. At the same time, sorting quality remains consistently high, regardless of the number of operating hours. In financial terms, these labour savings contribute substantially to the payback period of the investment.

Higher capacity, lower costs per tonne

Modern sorting lines equipped with optical technology process higher tonnages per hour. This allows the sorting process to be organised more efficiently and concentrated into shorter periods. This results in savings in energy consumption, logistics and handling.

Furthermore, optical sorting offers flexibility. Batches can be processed using different settings, depending on variety, market and delivery time. This flexibility makes it possible to sort strategically and thus respond optimally to price movements.

Data as an additional revenue stream

An additional benefit of optical sorting is the availability of detailed data. Every potato that passes along the conveyor belt is recorded. Insight into size distribution, quality and rejection rates makes it possible to manage cultivation, storage and planning more effectively.

This data supports better decision-making, such as crop allocation and delivery strategy. As a result, optical sorting not only contributes to today’s yield but also to a structurally higher return in the future.

An investment that pays for itself

Although the investment in optical sorting technology is higher than for a traditional sorting line, the payback period is often short in practice. Greater accuracy – yielding up to 25% more seed potatoes of the correct size – lower labour costs and more efficient processing make the business case compelling.

In a market where margins are under pressure and oversized potatoes yield little return, optical sorting is not a luxury, but a strategic choice. It ensures that every potato yields the maximum return and makes sorting a direct contribution to the operating profit.

Article from Boerenbusiness, 2 February 2026