Biosystems Engineering (2002) 83 (4), 433–440

doi:10.1006/bioe.2002.0139, available online at http://www.idealibrary.com on

PH}Postharvest Technology

Automatic Jalapen* o Chilli Grading by Width

Federico Hahn1,2
1
VIKSAL, P.O.Box 394, Zihuatanejo, Guerrero, M!exico
2
Departamento Irrigacio! n, Universidad Autonoma de Chapingo, Chapingo, 056230, Estado de M!exico, Mexico;
e-mail: bandido058@hotmail.com

(Received 9 June 2001; received in revised form 4 September 2002)

Jalapen* o chilli is a variety grown extensively in Mexico consumed by almost all the population. It has a high
processing demand and proper sorting is required before filling or canning. A sorter that classifies chilli by
three different width sizes was built. The conveyor used baby suckers to align each chilli during sensing. Chilli
width was determined by means of a photodiode scanner, which detected the incoming radiation sent by a
laser line generator. Chillies presenting necrosis were detected with a radiometer and removed to increase
product quality. The accuracy on the necrosis detection and width classification was of 96
3 and 87%,
respectively. # 2002 Silsoe Research Institute. Published by Elsevier Science Ltd. All rights reserved

1. Introduction Chilli is a basic nutritious product consumed by

The inspection and sorting of fruits and vegetables
can be very tedious work. In countries with cheap
labour, inspectors classify fruits and vegetables manu-
ally, but differences between visual standards and lack of
experience produce undesirable results (Peleg, 1985).
Machine vision classifying systems are efficient, consis-
tent and provide economic benefits. Howard and Searcy
(1989) studied carrot length, width, curvature and
perimeter to detect their shape. Fourier-based algo-
rithms applied to potato images to grade them accord-
ing to their shape were proposed by Tao et al. (1995).
Twenty-two different apple defects were identified using
image analysis techniques (Throop & Aneshansley,
1997) and classified using multilayer back propagation
algorithms (Miller et al., 1998). Modern automatic sorters
use individual bicone rollers to transport the fruit and to
present the entire fruit surface to the sensing camera
(Crowe & Delwiche, 1996; Throop & Aneshansley,
1999).
Structured light has been used in fruit detection to
help vision systems and Benady and Miles (1992)
detected the presence of melons during automatic
harvesting. Yang (1993) used it for detecting defects in
apples and Campins et al. (1997) for apple stem and
calyx identification. A chilli size sorter used structured
light to determine product length (Hahn & Mota, 1997a;
Hahn et al. 1997b).
almost all the population in Mexico. Jalapen* o chilli is
cultivated all around the country and a total of 15 219 ha
was planted in 1998 obtaining an yield of 192 590 tonnes
(INEGI, 1999). Sixty per cent of the chilli production
was processed, while 20% was sold as fresh vegetable in
supermarkets and grocery shops. The other 20% was
used to produce ‘chipotle’. The main quality features
found in Jalapen* o chillies are: their size ranges from 6 to
8 cm, they weigh at least 10 g, they are bright green in
colour and they have a peduncle to avoid bacteria and
fungi contamination (SARH, 1982). Some processed
chillies are refilled with cheese and prawns and are
exported to different countries. The desired width of the
chillies is about 40% of their length, and chillies that are
only 30% wider than their length are considered thin
and not proper for refilling. Chillies with the proper
width–length ratio are bisected, their veins removed and
then refilled.
Chilli sorting is done manually by experienced people
and a machine was developed to classify chillies
automatically taking their sorting judgement into
consideration. Chilli was classified into three different
width sizes and necrotic products were removed. The
effect of the sensing band inclination, baby suckers per
row and size on chilli alignment was studied. Chilli-
sorting accuracy was tested on fruits with and without
peduncles. Synchronized pulsing was used and chilli
misclassification owing to speed changes was evaluated.

1537-5110/02/$35.00 433 # 2002 Silsoe Research Institute. Published by

Elsevier Science Ltd. All rights reserved
434
Length and width measurements obtained for each volume category
Sorting class Feature
First (big) Length
Width
Second (medium) Length
Width
Third (small) Length
Width
100
80
Detection accuracy, %
60
40
20
0
Length Width
Chilli feature
Fig. 1. Length and width detection accuracy using as criteria: ,
volume; and , width/length ratio.
2. Theoretical considerations
Refilling chillies automatically is not an easy task, so
the sorting judgement of a panel of experts was
compared against real chilli measurements. Width and
length measurements from 1000 chillies were obtained
with a vernier. The volume of each chilli was obtained
using the Archimedes principle and three groups were
formed according to chilli volume. First and third class
chillies presented volume values ranging between 50–
65 ml and 20–35 ml, respectively. Maximum, minimum
and average measurements of length and width for each
volume group are shown in Table 1.
A panel of experts classified 300 chillies using their
own particular refilling standards. Volume is the best-
filling indicator, but if the length–width ratio is as
accurate from the panel’s point of view as volume, it will
be easier to sample. The chillies selected for the study
had minimum length and width values of 6.5 and 2.5 cm,
respectively. Expert subjective sorting was compared
with classification based on volume and width/length
ratio measurements. The experts correctly selected only
75% of the volume-measured chilli. Width–length ratio
was as effective in determining chilli size using expert
F. HAHN
Table 1
Minimum, mm Maximum, mm Average, mm
56 92 79
35
22 36 29
25
37 75 66
16
19 38 28
36
22 59 51
07
12 36 23
72
standards as volume. Misclassified chillies were shown
to the panel, who accepted that subjective measurements
were not always consistent.
On-line volume measurements are difficult to obtain,
so width-to-length ratio was used to determine the best
feature to predict refilling size. For both volume and
width-to-length ratio measurements, it was noted that
width was a better feature to sort chillies for refilling
(Fig. 1). Chillies that were going to be sorted by
width required non-overlapping thresholds. Chillies
under 24 mm in width were considered thin (third
quality) and were not used for filling. Chillies over
29 mm in width were considered top quality and those
ranging from 24 to 29 mm in width were considered
second class.
3. Equipment development and procedures
A prototype designed to measure produce volume was
used to study chilli width. Chilli width deformation and
misalignment was studied after acquiring chilli images at
5, 10, 20 and 308. The prototype used an ELECTRIM
1000N monochromatic charge coupled device (CCD)
camera (Electrim Corp., Princeton, NJ) to revolve
around the sampled chilli. The prototype (Fig. 2) uses
a white panel to reflect white light coming from the
halogen lamp. The object is back-illuminated providing
a shadow-free image. A stepper motor controlled the
movable arm geared by a chain and positioned the
camera at the right angle.
3.1. Sorter design
A system was designed with two 20 cm wide belt
conveyors. The second (sensing) band ran at a speed of
60 m min 1 sorting up to 15 chillies per second. The
speed of the second band was twice that of the first, and
separated chillies for individual sensing and sorting.
Chillies cannot roll owing to their peduncles, but when
they fall from the first band they bounce. The baby
suckers stop the chillies without causing impact
 JALAPEÑO CHILLI GRADING 435

Fig. 2. Prototype for measuring chilli features; CCD, charge coupled device.

Radiometer

Sizer
Piston
Sorter

Acrylic

Fig. 3. Conveyor belt for measuring chilli width and necrosis.

damages. An acrylic band below the surface belt allow
proper baby sucker positioning on the surface (Fig. 3).
Baby sucker rows are spaced 10 cm apart along the
entire belt surface. It is essential to position the chillies
parallel to the laser line to avoid erroneous measure-
ments.
Two sensors were used, one detected chilli necrosis
optically and the other measured chilli width (Fig. 3).
The first detector was a radiometer, which activated a
piston for removing chillies showing necrosis. The
chilli-width sensor was located close to the end of the
band and detected both vertical and horizontal chilli
widths.
Conveyor belts without individual bicone rollers
require an additional sorting device. This particular
sorter was required to classify three different-sized
chillies and mechanical sorting was implemented using
two flat metal sheets at the end of the conveyor belt
(Fig. 4). Two relays controlled the position of the metal
sheet that determined the trajectory of the chilli. During
the classification of the first size, the top plate almost
touched the band, letting the chilli fall to lateral band I.
436
Fig. 4. Mechanical sorting device.
The medium sized chillies fell on to lateral band II by
gravity without touching any plate. The small sized
(third) chillies rolled over the bottom plate, which is
guided to band III. During the sorting of the third size,
both sheets were separated from the band and only the
bottom plate relay was on.
3.2. Spectral detection of necrosis
One hundred healthy chillies and 100 showing
necrosis were measured using an OCEAN OPTICS
PC1000 computerized spectrometer in the 500–850 nm
range. A tungsten-halogen lamp (model LS1, Ocean
Optics, Dunedin, FL) provided the lighting on the
desired waveband and was regulated by a SOLA voltage
regulator. An optical bundle illuminated the sample,
and carried the reflected radiation towards a mono-
chromator. Spectralon diffuse reflectance material (Lab-
sphere, Inc., North Sutton, NH 03260) was used as
spectral reference due to its high reflectivity (98–99%) in
the 250–2500 nm range. Chilli spectra were acquired and
compensated using the dark and reference spectra.
Relative reflectance showed spectral differences at the
visible band (Fig. 5). Necrotic tissue absorbed all the
visible radiation and its reflectance peak at 720 nm was
twice that of the healthy tissue. The baby sucker
spectrum differed in magnitude and in shape from the
chilli spectrum.
A radiometer was built with two silicon photodetec-
tors, which measured the radiation passing through two
10 nm bandpass filters (EALING 35-3698 and 35-4217)
at 550 and 720 nm. Radiation was collected with a lens
directing it towards the photodetectors. The signal
obtained from both photodetectors was converted
to digital and sent to a 68HC11 MOTOROLA micro-
controller which activated a piston whenever the
ratio between the 550 nm value and the 720 nm was
lower than 0.1. A detector ensured that the produce
F. HAHN
100
80
Reflectance, %
60
40
20
0
500 557 609 661 714 766 818
Wavelength, nm
Fig. 5. Spectral signatures of chilli: , healthy tissue; ,
necrosis; , baby suckers
movement was synchronized with the radiometric
measurement.
3.3. Size detector
The width sizer consisted of a laser diode line
generator (Applied Laser, Pasadena, CA), which pro-
vided a structured vertical stripe and a bar of photo-
detectors standing vertically on the opposite side of the
band [Fig. 6(a)]. The photodetector bar consisted of 32
silicon photodiodes (HAMAMATSU, 1226-18BK,
Bridgewater, NJ) split 1.25 cm between them. Chillies
were always positioned with the peduncle facing the
laser.
Each chilli’s horizontal Wh and vertical width Wv was
evaluated. Horizontal width measurements were
obtained after counting the number of blocked laser
stripes as the chilli advanced through the conveyor belt.
The photodetector bar scanned the laser stripe every
20 ms [Fig. 6(b)], and photodetector values were com-
pared with a threshold. The digital outputs were saved
in the memory of the 68HC11 microcontroller. Another
silicon photodetector array (Hamamatsu, 1226-18BK)
positioned in front of the spot laser (Ealing, 21-6556)
detected the presence of the baby sucker [Fig. 6(c)]. The
0.9 mW spot laser was placed 35 cm ahead of the line
generator laser considering the maximum chilli width
(Table 1).
Sorting accuracy was tested with a trial group of 200
chillies, initially with the peduncle and subsequently
without it. A bigger trial group of 1000 chillies was
tested taking into account an optimum inclination, baby
suckers and speed compensation to know the final
machine efficiency.
 JALAPEÑO CHILLI GRADING 437

Chilli
Photodetectors Wh

Baby

Size
sucker
WV

1 2 3 4 5 6 7 8
(a) Band (b) Sample

Photodetectors Photodetectors

Line Spot Line Spot

(c) laser laser (d) laser laser

Fig. 6. (a) Laser line generator (laser stripe) and photodetectors; (b) sampling measurements taken with the photodetectors; (c)
well-aligned chilli; (d) badly aligned chilli; Wh, chilli horizontal width; Wv, chilli vertical width

4. Results and discussion Table 2

Average horizontal width increments for variable length chillies
A sensorial analysis carried out by a panel of experts having different inclinations in front of the sensor
evaluated chilli width as the best feature for classifying Chilli length, mm Average horizontal width increment
chillies for refilling. Chilli inclination is crucial during based on chilli inclination, %
horizontal width sensing and the prototype (Fig. 2)
58 108 208 308
which rotated a CCD camera around the products
measured width under different inclinations. Horizontal 60 14
47 25
96 74
47 95
74
and vertical widths were measured for 200 chillies. Chilli 65 10
5 39
52 67
53 110
70 5
96 19
54 47
37 89
47
back-illuminated images with a 308 inclination showed 75 7
22 20
5 55
54 106
22
horizontal widths twice that of real width measurement. 80 9
66 20
33 53
33 83
33
Table 2 shows that chillies of 6.5 and 8.5 cm in length 85 17
02 25
53 74
89 112
76
show increments of 110 and 112.76%, respectively.
Horizontal width measurements also increased when
chilli shapes curved closer to the apex. Straight chillies suckers prevents chilli damaging, and the flexible rubber
without curvatures showed similar horizontal and structure helps to reduce chilli bouncing. Band slope is
vertical diameters, with an overall average diameter important to chilli alignment but limits band length. If
ratio of 0
96. the number of chillies to be sorted increases, additional
As chilli misalignment produces sorting errors after parallel bands should be added.
passing in front of the laser sensor, conveyor belt Chillies from each of the three different sizes were
performance was tested in three different experiments to placed on the first band and their alignment with respect
detect the causes of misalignment. The first of three tests to the laser sensor was measured manually. The sensing
studied how chillies pass from the first band to the band had a 58 slope and two baby suckers per row.
sensing band. The second test analysed the effect of the Misalignment problems resulted from chillies bouncing
slope of the sensor belt on chilli alignment. Finally, or turning on the sensing belt after falling from the first
misalignment caused by using rows of two or three baby band. Turning is produced when the stiff peduncle
suckers was studied. In a previous chilli-sorting proto- touches the sensing band before the body of the chilli.
type developed by Mota (1996), the peduncle was often When this happens, the chillies rotate one-quarter turn
separated from the base of the chilli, reducing its quality and can advance or retrocede. If the body touches the
and increasing postharvest losses. The use of baby band before the peduncle, the chilli only bounces.
438 F. HAHN
Bouncing and turning caused improper positioning in
more than 60% of the chillies, independent of product
size. It should be noted that first and third class chillies
presented misalignments of more than 158 for 37.7 and
41.6% of the sampled products (Table 3). Bouncing
disappears in chillies that have been stored for more
than 36 h at 208C as their texture changes.
In the second experiment, chillies were placed on top
of the sensor band to study misalignment caused by
band inclination. The slope of the sensor band was
modified and chillies slipped until they stopped at the
baby suckers. Once the chilli stopped, its inclination
with respect to the laser scanner was evaluated
manually. The baby sucker acted as a trap or break-
point, which limited chilli slipping. With the peduncle
side heavier, chilli slipped turning around the centroid.
Rotation depended on where the chilli hit the baby
sucker and less turning occurred when the contact
was near the centroid. It was noted that 83
7% of
the chillies were properly aligned when the
slope of the sensor band was increased to 158.
With a 58 slope, only 35.4% were properly
aligned (Table 4).
The effect of the number of baby suckers per row on
chilli alignment was studied in 100 chillies. Chillies were
placed 5 cm away from the baby sucker and after the
sensor band was turned on, the chillies slipped until they
stopped at the baby suckers. As with previous experi-
ments, chilli inclination was evaluated manually. When
two baby suckers were used, the peduncle attached itself
to the baby suckers on several occasions, causing
improper positioning. Chillies aligned orthogonally to
the laser scanner showed huge widths. Misalignment on
50% of the sampled chillies was encountered on the 158
sensor band slope when only two baby suckers were
used in each row. Inserting a third baby sucker in each
row with the same sensor band slope increased proper
chilli alignment to 85%. In previous designs, baby
sucker size was important for sensor performance, with
the larger baby suckers working better. Nevertheless,
they required larger photodetector coverage. With the
Table 3
Percentage of different sized chillies aligned at 0, 10 and 15
degrees in front of the laser scanner after falling from the first
band
Sorting class Proportion of chilli at various alignments, %
08 108 158
First (big) 44
4 17
7 37
7
Second (medium) 35 25 40
Third (small) 35
4 22
9 41
6
Table 4
Third class chilli alignment according to band inclination
Band slope, Proportion of chilli at
deg various alignments, %
08 108 158
5 35
4 22
9 41
6
10 66
3 7
1 26
5
15 83
7 2
5 13
7
addition of the spot laser, baby sucker size did not affect
final chilli width measurements.
The microcontroller program executed three different
routines: the waiting cycle, the product passing routine
and the baby sucker detection. During the waiting cycle,
all the photodetectors were on, as no chillies interfered
with the laser stripe and the spot laser. The microcon-
troller did not obtain scanned data from the photo-
detector bar for storage. Once the chilli blocked part of
the laser stripe, the microcontroller was interrupted,
saving the scanned data on memory. In this product
passing routine, the photodetector in front of the spot
laser remained on, until the baby sucker appeared. In
the baby sucker routine, the spot laser beam gets
blocked and the scanned data from the photodetector
bar was not acquired by the microcontroller memory.
The program cycles back to the waiting routine, once
the photodetector bar detects the full laser stripe. The
number of memory locations stored in the microcon-
troller memory provided the horizontal width of the
chilli.
Each scan shows a different number of photodetectors
that do not receive the laser stripe, this quantity being
saved in the microcontroller memory. The maximum
value saved in the memory corresponded to the vertical
width. Both horizontal and vertical chilli widths were
compared and when the values differed, the minimum
value was chosen. The final width value was thresholded
in order to activate the mechanical sorter relays.
Considering that the chilli-feeding to the band is
constant and the weight is not considerable, speed
changes could only be caused by the line power supply.
Speed changes caused problems in chilli width detection
when fixed time sampling was used. A decoder was
introduced to synchronize the sampling period with the
band speed in an effort to increase sorting accuracy
(Mota, 1996).
The sorting sensor was evaluated after checking chilli
alignment performance. Two hundred chillies were
placed on the second band to avoid bouncing and the
effect of the peduncle on the laser measurements was
studied. Chillies without peduncles were sorted with
better accuracy, with first class chillies having the
 JALAPEÑO CHILLI GRADING
Table 5
Sorting accuracy for each chilli class with and without peduncle
Sorting class Sorting accuracy of chilli without peduncle, %
Normal scan Controlled scan
First (big) 92
2 93
1
Second (medium) 91
1 92
2
Third (small) 90
1 91
7
highest sorting accuracy (Table 5). Third class chillies
with and without peduncles achieved success rates of
84.3 and 90.1%, respectively. Horizontal width mea-
surements increase when the peduncle blocks some of
the photodiodes, while vertical width measurement will
provide a closer measurement. The laser system can
improve its performance if slight modifications are made
to the program. It should include a routine, which could
eliminate the peduncle, taking away thin measurements
or using first derivatives.
Controlled scanning used a decoder, which was fixed
to the motor that moved the conveyor belt. The sensing
period varied according to band speed, and overall
sorting accuracy increased (Table 5). First class chillies
with peduncles showed success rates of 92.3 and 91.3%
in controlled and normal scanning, respectively.
A trial group of 1000 chillies was tested taking into
account an optimum inclination of 158, with three baby
suckers per row and speed compensation, and the final
results obtained are shown in the last column of Table 5.
Both bands were used and no substantial sorting
accuracy difference was noted between the three groups.
The basic misalignment problem was caused when
chillies passed from the first band to the sensing band.
Heavier first class chillies bounced more and presented
more misalignment problems, but the 35 mm distance
limit imposed by the program did not allow any degree
of misalignment on first class chillies. The program
limited horizontal width measurements in curved chillies
to 35 mm and the sorting value was always the vertical
value width. The program worked efficiently and only
the minimum horizontal or vertical width measurement
was considered. However, an error was detected
whenever a chilli peduncle faced upwards at 608 angle.
Both vertical and horizontal widths increased with
respect to their normal values.
On-line necrosis measurements were 85% accurate
when only the relative reflectance at 550 nm was used. A
reference measurement was taken every 5 min and used
to obtain the relative reflectance. The reference mea-
surement is not practical for on-line sensors, so a
reflectance ratio between 550 and 720 nm was used. Five
hundred necrotic and 500 healthy chillies were used as a
439
Sorting accuracy of chilli with peduncle, %
Normal scan Controlled scan Both bands
91
3 92
3 87
2
89
2 90
2 86
2
84
3 87
3 87
1
trial group. The 500 necrotic chillies were placed with
the damaged part facing upward in the sensor band. The
signal obtained from both photodetectors was acquired
by the microcontroller, which activated a piston when
the reflectance ratio was close to zero. Detection of
necrotic samples was achieved with a 96
3% success
rate.
Necrosis radiometric measurements worked well, but
as the chilli remained static only the top view was
analysed. If necrosis appears in another area, the
machine will not detect it; therefore, rollers are required
to rotate the product in front of the radiometer. Bicone
commercial rollers should be modified for careful chilli
handling to avoid peduncle ruptures and to take
different peduncle sizes into account.
Chilli-width sensing was over 90% accurate, while the
entire system sorting efficiency was of 87%. Five of
every 100 chillies were misclassified due to improper
positioning in front of the sensor. Imaging techniques
should be used to increase sorting accuracy. Two
cameras viewing the top and lateral chilli sides should
detect chilli horizontal and vertical widths, respectively.
5. Conclusions
The system is reliable as it classifies chillies by width
with extreme efficiency. It is a very cheap and simple
system, easy to clean and to repair, and it can be
installed in warehouses at production sites. Although
image technology can be used successfully to detect chilli
size, most rural places where chillies are sorted prefer
simple systems, which do not depend on sophisticated
technology. Lack of proper service and maintenance,
and difficulties in getting replacement parts are the main
reasons for acquiring simple machinery. High moisture
contents and dust in the countryside are some of the
other problems encountered on field machinery.
The following conclusions can be drawn from this
study.
(1) Although volume is the best-filling indicator, the
width/length ratio is as accurate from a panel of
expert points of view.
440 F. HAHN
(2) The best band parameters are given at an inclina-
tion of 158, three baby suckers per row and speed
compensation.
(3) The width sorter measures horizontal width using
laser stripes, limiting the maximum size to 35 mm.
The width sorter measured the vertical width using
a photodetector array. A spot laser detected the
baby sucker presence.
(4) The minimum horizontal or vertical width gave the
final width.
(5) First class chillies were sorted with success rates of
92.3 and 91.3% with and without speed scanning,
respectively.
(6) Chilli necrosis was detected with a 96.3% accuracy
using a radiometer, which measured at 550 and
720 nm.
Acknowledgements
I would like to acknowledge Ing. Francisco Rafael
and M.C. Rafael Mota for their help in gathering the
data and Lisa Harrison who made this paper readable.
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