Designing a 2 in 1 weighing scale and sorting machine for

egg grading with labeled egg trays to avoid confusion in

sorting

Novielyn A. Agustin, Yuri Mark Christian N. Ancheta, Kyrelle Anne G. Bautista,

Jaimie M. Concepcion, Riza Bee F. Zamora

Department of Industrial Engineering

Bulacan State University

City of Malolos, Bulacan, Philippines

novielyn.agustin.a@bulsu.edu.ph, yurimarkchristian.ancheta.n@bulsu.edu.ph,
kyrelleanne.bautista.g@bulsu.edu.ph, jaimie.concepcion.m@bulsu.edu.ph,
rizabee.zamora.f@bulsu.edu.ph
1. Introduction

1.1 Background of the study

Egg sorting is a crucial process in the egg production industry. It involves separation of eggs based on their
quality, size and weight. This process is essential to ensure that only high -quality eggs are sold to consumers. In the
past, egg sorting was done manually, which was time-consuming and prone to errors. With the advancement of
technology, egg sorter machines have been developed to automate the process, making it faster and more efficient.

Table egg products are typically separated in public markets and supermarkets in the Philippines according
to size and quality. Egg quality is determined by factors including the amount of dirt and cracks present as well as the
internal qualities of the eggs. On the other hand, grading based on size entails sorting depending on how much each
egg weighs. Since it helps the egg industry make money, maintaining egg size uniformity is essential.

Table eggs can be categorized into eight (8) different groups, according to the Bureau of Agriculture and
Fisheries Products Standards from 2005. In order to classify weights, they have created a standard that details the
weight range for each category.

Table 1 - Weight Classification of Table Eggs According to BAFPS, 2005.

Most often, sorting is accomplished by manually weighing table eggs on a weighing scale. Even today, many
small-scale egg farm workers still use manual labor. To prevent cracking or breaking of the eggs during this method
of sorting, care must be taken when handling the eggs. Weighing becomes subjective in the absence of a digital scale
since weight readings depend on the observer. When analog weighing scales are utilized, reading errors related to
operator weariness and judgment get higher. Additionally, using the manual process is more expensive and inefficient,
especially when dealing with a greater volume of table egg products.

Manual grading of eggs can be a time-consuming and labor-intensive task and it can also be prone to errors.
Some of the common problems encountered in manual grading of eggs are inconsistent grading. Different graders
may have different criteria for grading eggs, which can lead to inconsistencies in the grading process. Manual grading
can be prone to errors due to fatigue, distraction or lack of attention to detail.
1.2 Discussion on the Observed Ergonomic Problem

To overcome these problems many egg producers use egg sorter machines to accurately and efficiently grade
eggs. The main purpose of the study is to design an Egg sorter that is easy to operate, with clear instructions and
feedback for the operator. The system could also be designed to minimize cognit ive load and to improve efficiency
and reduce the risk of errors or accidents.

Manual grading and sorting of eggs needs focus and concentration while doing the task in order to lessen
human error. Mistakes in grading and sorting the eggs can be related to the workers judgment and fatigue while doing
the task.

1.3 Objective of the study

This study aims to design an egg sizing and sorting machine to decrease the human intervention of the operator and
workers with accuracy and efficiency.

The focus of this study is to:

● Designing a machine to weigh and sort eggs based on weight and size.
● Minimizing confusion in the sorting process with labeled egg trays.
● Focusing on engineering and design aspects of creating the machine.
● Considering human factors to ensure user-friendliness.
● Analyzing cognitive processes involved in egg grading and sorting to optimize performance.

1.4 Significance of the Study

Egg Industry. The study’s findings will provide a new and innovative egg sorting technology th at will lessen
the cost in electricity. It will lessen the chance of error and improve the accuracy of egg sorting.

Workers. The study will provide them help not only in physical but also in their cognitive ergonomics that
will make their jobs a little easier through the use of the new design for egg grading and sorting.

Researchers. Through the conducted research study, the researchers may gain a deeper understanding of
how to examine a current system and find methods to improve other present systems to develop new product designs
that will benefit other people. It may serve as a practice for the researchers to enhance their critical thinking, decision
making, and problem-solving, which will be helpful in the future.

Future Researchers. This study can be a starting point for undertaking related research, especially for
Industrial Engineering students. With that, it will be easier for them to conduct a r elated study and collect information
on how to develop product designs for further improvement of different systems.
1.5 Scope and Limitation

The study is focused on finding the best product design in egg weighing and egg sorting to reduce human
error. The study is conducted at the 2K2 farm company in Marilao, Bulacan since this company sorts eggs semi-
manually. The researchers mainly focused on the egg sorting process involved in 2k2 farm. The researchers used six
size categories of egg: jumbo, extra large, large, medium, small and peewee in designing the egg sorter. Additionally,
the target respondents of this study are three workers in 2k2 farm. The study will not cover other matters in the 2k2
farm company. Other concerns like the cleanliness of the egg, food safety, worker safety, and marketing are not
included in this study. This study will be conducted from April 2023 to May 2023.

2. Review of Related Literature

The egg industry has been transformed by the design and operation of a computer vision-based automatic
egg sorting system. The framework utilizes PC vision calculations to distinguish and arrange eggs in view of their
quality and size. The framework is furnished with a high-goal camera that catches pictures of the eggs as they move
along the transport line. The computer vision algorithms then examine the images to ascertain the eggs' quality.

The egg sorting machine is made to be very accurate and efficient. It has the ability to sort hundreds of eggs
per minute with high precision. Additionally, the system can sort eggs according to their size, which is crucial to the
egg industry. Eggs that are either too small or too big to sell can be detected and sorted by the system, which reduces
waste and boosts profitability.

The programmed egg arranging framework is additionally intended to be easy to understand. Operators can
easily monitor and control the system thanks to its user-friendly interface. Additionally, the system is intended to be
simple to maintain and repair, minimizing downtime and boosting productivity.

The accuracy of the computer vision algorithms has a significant impact on how well the automatic egg
sorting system works. Eggs can be identified and categorized using these algorithms based on a variety of
characteristics, such as size, shape, color, and texture. In order to guarantee that the system can accurately identify
and classify eggs under a variety of conditions, the algorithms are constantly being improved and refined.

Jakhfer Alikhanov et al. (2019) stated that there are some fundamental mathematical boundaries of the eggs,
to be specific: Image processing algorithms are used to get the minor and major axes, area and perimeter, shape factor,
and shape index. The weight is surveyed from the mathematical boundaries utilizing a relapse model. The proposed
system's sorting precision is evaluated for two different speeds of transport conveyors—two eggs per second and three
eggs per second, respectively. The overall sorting accuracy in each case is found to be 94.6 percent and 90.3%,
respectively.

Different studies were conducted for its development. Mitchell et al. (2013) designed an egg bundling
framework which permits eggs to expect to be a specific direction inside the bundle. The project was about egg
processing systems and techniques. The study looked at the various steps eggs go through before they reach
consumers; these include washing, candling, weighing, grading, and packaging into a variety of commercial
containers, including cartons and crates. Some of these systems produce a lot of work in August 2020, according to
the 8th UMTBIC. Some systems have the capacity to process as many as one million eggs per day and as many as
20,000 eggs per hour. Eggs must be marked with their expiration dates because they are perishable and susceptible to
spoilage. The use of vegetable water-soluble dyes for marking was one method that was introduced, but it was
unsuccessful. These markings could disappear or get inside the egg. As a result, the expiration date will not be visible,
which is not a good strategy. This study aimed to alleviate the issue with laser marking, which made it simple to
determine an egg's expiration date.

Quilloy et al. (2018) focused on using mechatronics and machine vision to separate eggs. The machine
created included a taking care of, figuring and an arranging unit. During the sorting process, the machine vision
software called ECGSoTiC was utilized. The machine's ability to produce consistent results was demonstrated by a
test for reading similarity. The dynamic test's results for about 100 egg samples had an accuracy of 91 percent. The
mean squared error, the evaluation metric, revealed that there were no significant errors, indicating the machine's
performance.

The egg industry has been transformed by the development and operation of a computer vision-based
automatic egg sorting system. The system is a valuable asset for egg producers worl dwide due to its high efficied
characterize eggs under different circumstances.ncy, accuracy, and ease of use. The framework is likewise
exceptionally reliant upon the precision of the PC vision calculations, which are continually being refined and
improved to guarantee that the framework can precisely identify and characterize eggs under different circumstances.

In a study of Sevilla (2010) that developed an automatic egg sorting, counting, and packaging machine that can
process eggs with less human intervention. This project uses an infrared sensor that detects eggs that are sent to
Arduino and presents the number of eggs for counting. While in packaging eggs use a light dependent resistor that
sends signals to the motor when to start that is together with vacuum pump for transferring eggs.

According to a study conducted by Quilloy and Bato (2015) , a progressive machine that functions using vision
software in grading and sorting of eggs resulted in 92 percent accuracy.

According to a study by Nasir, A., et al (2018), in a system of egg grading that compared computer vision and using
parameters of egg shapes versus using weight measurement resulted in many different egg classification using the
parameters of egg shape. The results show that an automated egg grading system that uses computer vision is
suitable in terms of grading eggs in shape based features since it uses pictures while the system that uses weight of
eggs is more reliable in using weight grading systems.

According to Alikhanov, J., Penchev, S. M., Georgieva, T.D., Moldazhanov, A., Shynybay, Z., Daskalov, P.l.,
(2017)The paper proposes a new way to sort eggs by weight using image processing. They use math to find the
relationship between an egg's weight and its size and shape. They compared the data from image processing with
traditional methods and found that egg area was the most important factor for determining weight. They created a
math model with very good accuracy (97.8%) and were able to sort the eggs into four weight classes with an error
rate of 2.5% for the test set and 12.5% for the training set

Patent Search

The following patent search will be considered in accordance with the possible solution to be made. These
will be used as reference and comparison in formulating alternatives.
CN214102792U. The application relates to an egg separator, which comprises a support column and a separator body
arranged on the support column, an illumination box is arranged on one side of the separator body, the illumination
box is hollow and rectangular with an opening at the upper end, two groups of conveying components which are
arranged at intervals are arranged between two opposite sides of the upper end of the illumination box in the width
direction in a transmission way, and the two groups of conveying components are arranged in an inverted splayed
shape along the length of the illumination box, the two groups of conveying components jointly transmit eggs to the
sorting machine body, an illumination component is arranged in the illumination box, the illumination component is
positioned right below a gap between the two groups of conveying components, the illumination component is used
for inspecting the damage of the eggs by illumination, before carrying out weight classification to the egg, can s hine
the inspection to the egg earlier, this application has the effect that can improve the quality of producing of egg.

US2687802A. The machine illustrated is particularly designed for the grading or sorting of eggs by Weight, various
features of the machine being adapted and useful for grading other objects to be sorted by weight. The details of the
embodiment. illustrated are adapted for handling fragile objects.The frame designated generally by the numeral l is
designed to support the various parts in their proper relationship and will not be described in detail except as reference
will be made to parts thereof with which parts to be described are directly associated or supported. The frame illustrated
is largely made up of available structural material.Generally stated, the machine comprises means for feeding or
supplying objects to be sorted to a vertically reciprocating elevator or support which is adapted to receive a plurality
of the objects in aligned relation. A series of scales are disposed in aligned relation, desirably divided into groups. The
scales of the several groups are graduated so that objects of predetermined weight will actuate the scales of the first
group and objects of a lesser weight will actuate a succeeding group.

CN111014043A. The invention discloses a poultry egg sorting and selecting machine suitable for different sizes,
which comprises a main frame, a movable sorting mechanism, a limiting plate, a fixed sorting mechanism and poultry
eggs, wherein the movable sorting mechanism is flexibly matched with the fixed sorting mechanism, before the poultry
eggs are sorted, an upper sorting plate firstly slides downwards to be right above a lower sorting plate, then the cleaned
poultry eggs are sequentially placed into a large sorting hole of the upper sorting plate, after the poultry eggs are
placed, a screw motor is opened to drive a fixed screw to rotate, a movable sliding block upwards drives the upper
sorting plate to move upwards, the poultry eggs with larger apertures are left in the large sorting hole and ascend along
with the upper sorting plate, the poultry eggs with smaller apertures pass through the large sorting hole and are left in
a small sorting hole of the lower sorting plate, and then the poultry eggs are f urther screened by disassembling and
installing other upper sorting plates and lower sorting plates with different apertures, the sorting is quick and
convenient, the consumed time is short, and the probability of generating errors is low.

US20220174912A1. The egg sorting device includes an image data acquisition unit that acquires image data
representing an image obtained by photographing an egg; a first determination unit that determines a state of an egg
according to image data acquired by the image data acquisition unit by a learning model trained using training data
including information indicating a state of an egg and image data related to the egg; and a decision unit that decides a
classification of the egg according to a determination result of a state of an egg.

DE2444179A1. This invention is about a device that sorts eggs by weight, making it easier to package them for sale.
Usually, eggs are washed and then x-rayed to remove any that are not good for packaging. Then, they are sorted into
classes based on weight, with six classes ranging from Jumbo to PeeWee. The weight range for each class is set by
regulations or customer preferences. The device would help to streamline the process of sorting eggs by weight and
ensure that each packaging machine receives eggs of the same weight class for packaging.
US10532839B2.An egg sorting and packaging assembly comprising an endless egg conveyor, an egg supply device
for supplying and moving eggs onto the endless egg conveyor, and one or more packaging lines associated with the
endless egg conveyor. The one or more packaging lines are configured and arranged to receive eggs from the endless
egg conveyor. The egg supply device is adapted and arranged to remove eggs from the supply device that would have
to be placed on a position on the endless egg conveyor that is already occupied by an egg that could not be received
in a packaging line, and leads the removed egg back to an egg supply line.
US2687US2687802A
3. Material and Methods

To ensure consistency and consumer satisfaction in the field of egg grading, precision and accuracy are
essential. To do this, a lot of farms and processing facilities sort eggs based on size and weight using weighing scales
and sorting equipment. But if done incorrectly, this process can be difficult and time-consuming. In order to avoid any
confusion while sorting, we're offering a novel method that combines a weighing scale and a sorting machine into a
2-in-1 machine with labeled egg trays as an extra feature. This strategy will simplify the egg grading procedure while
simultaneously improving accuracy and productivity over time.

3.1 Materials

These following are the necessary materials for the product design development and the bill of materials,
Although the bill of materials is not very accurate, it is in the estimated range, it can be lower or higher.

No. Materials Bill of Materials

1 Wood (plywood) Php 2000

2 Cloth Cushion for eggs Php 200

3 Analog Weighing Scale Php 50

4 Springs Php 50

5 6 buttons Php 72

6 Wire Php 100

7 Metal piece Php 150

8 Screws and Nail Php 150

9 Metal Sheet Php 300

10 Paint Php 500

11 Labor Php 1500 - 2000

Total : Php 5072 - 5572

 The Proposed design egg separator is made of wood, it may seem big but rest assured that it can be smaller
or bigger depending on the demand of the customer. The main concern in this design is the Egg Sorting Mechanism
and Egg Weighing Mechanism. The egg weighing mechanism works like a normal analog weighing scale that moves
the arm depending on the weight of the egg. After that the arm in the egg sorting mechanism will move to the
designated size of the egg and they just need to let the egg roll through th e partitions and slopes. Once the egg passes
through the button the egg sorting arm will reset to the middle to be ready for the next egg to be weighted. With the
proper cushioning we ensure that the egg will have no damage and because of the cushioning th e egg will roll at a
slower pace.

Product Design Drawings

To access the files regarding the drawing of the product design:

https://drive.google.com/drive/folders/1l6AL53N2uhnJ6HJQ1ApN0tNc0IZMd-2W?usp=share_link

Figure 1.1.1 - Dimensions of Egg Sorter

 Figure 1.1.2 - Sorting Labels

Figure 1.2.1 - Weighing Mechanism Dimensions

 Figure 1.2.2 - Weighing Mechanism Inner Parts

Figure 1.2.3 - Weighing Mechanism Isometric View

Figure 1.3.1 - Sorting Mechanism Upside Down

Figure 1.4.1 - Top View

Figure 1.4.2 - Front View

Figure 1.4.3 - Back View

Figure 1.4.4 - Left Side View

Figure 1.4.5 - Right Side View

 Figure 1.4.6 - Isometric View

Figure 1.5.1 - Top view of sorting and weighing mechanism

Figure 1.5.2 - Close up view of sorting and weighing mechanism

Figure 1.5.3 - Close up view of egg sorting slope

 Figure 1.5.4 - Close up view of egg grade and size partition

3.2 Product Design Development

INPUT PROCESS OUTPUT

• Observation Initial Ergonomic Possible work areas with ergonomic

Audit problems
• Interview

• Video Ergonomic Analysis Identified a specific ergonomic problem as

• Descriptive Analysis well as recommended solution

• Workers population
• Ergonomic principle and Develop Ergonomic Cognitive ergonomically designed product
guidelines Interventions
• Patent search for existing
designs
• Cost benefit analysis

• Best solution and alternative Evaluation of ergonomic improvement and

for Ergonomic Improvement Evaluate Ergonomic design modification for further improvement
Improvement if needed.
 Table 2. Methodological Framework

Table 2 shows the methodological framework of the study. The framework includes the input, process, and
output. Mainly, there are four processes that will be done with the corresponding input and output throughout the
study. First is the initial ergonomic audit wherein the researchers will identify the areas with ergonomic problems
present through observation and interview. Second is the ergonomic analysis in which the results coming from the
workers will be analyzed and interpreted. Next is to develop a product design as an ergonomic intervention, Lastly,
evaluating the ergonomic improvement and the product developed itself if there is a need for further improvement.

Figure 2 - Process Flowchart

Figure 2 shows the process and procedures that the workers do to sort the eggs. The process starts from the
placing or loading of the eggs to the machine, then the machine will do its job sorting the egg. Then after the
machine determines which class or size the eggs are, they will roll on the designated area where the workers get the
egg and place it on the dedicated egg tray by size.
3.3 Design Metrics

The objective of this study is to develop a tool that will be useful to the workers. Criteria that measure the
effectiveness of potential solutions will be provided by identifying the issues and recommendations. The following
criteria will be used with the corresponding ratings: performance (30%), reliability (30%), cost effectiveness (20%),
and ease of use (20%).

Table 3. Ergonomic Criteria

CRITERIA
RATING

Performance 30%

Reliability 30%

Cost Effectiveness 20%

Ease of Use 20%

Total 100%

3.4 Data Analysis

Researchers will gather information and data from a poultry farm that collects and sorts eggs. In this study,
the results will be interpreted by descriptive statistics. The data collected together with the results will be analyzed
and explained with the help of tables and graphs. In doing so, there will be a basis in investigating the workplace and
workers if there are existing cognitive ergonomic problems.
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