Pack2Spec™ is a patented system that maintains desired product specifications by analyzing downstream product quality and automatically adjusting upstream sorter thresholds for more or less aggressive sorting on specific targets.

Company: Qcify

In industrial sorting processes, maintaining a consistent product grade throughout a production run remains a persistent challenge. Variability in incoming product, machine behavior, and processing conditions causes quality to drift over time. Today, most sorting lines are monitored and adjusted manually: operators periodically check product quality and modify machine settings based on these observations. While effective to a degree, this approach is inherently slow and inconsistent. As a result, deviations from the desired grade are often detected too late, leading either to unnecessary product rejection or the need to reprocess batches—both of which increase cost and can result in avoidable waste of edible product.

Pack2Spec™ is designed to eliminate this inefficiency by introducing automated, continuous grade control based on real output quality. The system establishes a closed feedback loop in which the product is first sorted and then objectively measured at a defined inspection point. Using systems such as the Qcify AIR, Qcify EYE, and Qcify RAY combination for in-line verification, or the Qcify 360 with auto-sampler for final validation before packaging, Pack2Spec™ continuously evaluates the actual accepted product stream.

The measured results are compared against a predefined grade specification, and any deviation is translated into automatic adjustments of upstream sorting parameters. This process runs continuously during production, allowing the system to respond immediately to changes in product conditions without requiring operator intervention.

To ensure stable operation, Pack2Spec™ applies configurable sampling windows and minimum data thresholds, ensuring that adjustments are based on statistically reliable information rather than short-term fluctuations. It also supports complex configurations, such as multi-channel systems like the Qcify AIR, where individual streams can be controlled independently within a unified framework.

By shifting from manual, reactive adjustments to automated, data-driven control, Pack2Spec™ enables producers to maintain consistent quality, reduce unnecessary rejection, and minimize reprocessing—resulting in both economic and sustainability benefits.

Pack2Spec™ is designed for industrial processors of tree nuts, peanuts and dried fruits, and can possibly be extended to other food applications where consistent grading, yield optimization, and automated quality control are essential.

What makes our product unique?

Pack2Spec™ introduces a fundamentally different, patented control architecture based on downstream validation, addressing key limitations of both manual processes and conventional automated systems.

In traditional sorting lines, adjustments are made either manually or based on internal machine signals. Manual workflows rely on periodic sampling and operator intervention, which introduces delays and variability, while internal feedback systems derive decisions from indirect indicators such as incoming product characteristics or sensor data. These approaches do not validate the actual accepted output and can lead to incorrect decisions—especially in complex scenarios such as blended product streams, where incoming characteristics do not directly reflect final quality.

Pack2Spec™ overcomes these limitations by basing all control decisions exclusively on validated output. The core innovation lies in the structural separation between sorting and validation: control decisions are made only after a product has passed the sorting stage and its quality has been objectively verified. This ensures that the system continuously optimizes for the true end result—the final product grade—rather than indirect indicators.

The architecture is designed to work seamlessly with different validation methods. High-frequency, in-line inspection can be achieved using integrated solutions such as the Qcify AIR combined with Qcify RAY or Qcify EYE, enabling rapid response to process changes. For applications requiring statistical verification, the Qcify 360 with auto-sampler provides batch-based validation, linking final quality checks directly back to upstream process control.

Additionally, Pack2Spec™ supports multi-channel and multi-pass systems, allowing individual product streams to be adjusted independently within a single control model. Combined with built-in stabilization logic and minimum sampling thresholds, this prevents overcorrection and ensures consistent, stable performance over time.

By combining downstream validation, automated control, and flexible system integration, Pack2Spec™ delivers a level of accuracy and reliability that is not achievable with internal feedback systems or manual adjustment workflows.

For more information: https://qcify.com/Pack2Spec