Automated Tobacco Stem and Leaf Classification with SPECIM FX10 Hyperspectral Camera
The advancement of automated technologies has transformed the way tobacco materials are processed and classified, particularly in distinguishing between leaf and stem components that determine overall product quality. Traditional manual sorting methods, while effective in experienced hands, are slow, labor-intensive, and prone to inconsistencies caused by human subjectivity. To overcome these limitations, modern processing facilities are increasingly adopting machine-based solutions that combine imaging systems to achieve faster, more reliable, and objective classification. Among the most promising innovations is hyperspectral imaging (HSI).
Hyperspectral Imaging: A High-Tech Solution for Tobacco Sorting
HSI represents an advance imaging technology that integrates conventional imaging with spectroscopy to capture detailed spectral information across a wide range of wavelengths for every pixel in an image. Unlike standard RGB or multispectral imaging, which only collects data from a few spectral bands, HSI captures hundreds of narrow and contiguous spectral bands, allowing for precise identification of material composition and subtle differences in physical and chemical properties. In the context of tobacco processing, the HSI technology enables automated systems to differentiate leaf and stem components based on their unique spectral signatures, ensuring better classification accuracy and consistency, facilitating real-time quality control and process optimization in tobacco manufacturing.
At the heart of this setup is the Specim FX10e hyperspectral camera, a high-speed imaging sensor designed to see far beyond what the human eye can detect. Operating across the 400â1000 nm range, it captures information from both visible and near-infrared light, revealing subtle differences in the composition and structure of tobacco materials. The FX10e hyperspectral camera works in tandem with Specimâs Lumo software, which handles data collection, and SpecimINSIGHT (version 1.3.72), which processes the spectral data to classify materials, forming an integrated HSI system.
As the tobacco moves along the production line, the Specim FX10e hyperspectral camera continuously scans and analyzes every pixel in real time, without ever touching or damaging the product. This enables the HSI system to instantly distinguish leaves from stems by recognizing their unique spectral signatures. The result is a smooth, fully automated workflow that replaces slow, manual sorting with a faster, more consistent, and data-driven solution, ensuring every batch of tobacco meets its desired quality.
Proof of Concept: Clear Separation of Stems and Leaves
The hyperspectral classification results reveal a clear visual distinction â tobacco stems and leaves appear in red and green, respectively. Using the Specim FX10e hyperspectral camera in conjunction with SpecimINSIGHT software, this proof-of-concept test successfully demonstrated the automatic separation of stems and leaves. As shown in the false-color image above, the color coding wasnât manually annotated, but generated by the HSI systemâs model itself, which had been trained to recognize subtle spectral differences between the two materials.
One interesting discovery from the test was that the reflectance contrast between tobacco leaves and stems is most significant in the 520â810 nm wavelength region. Within the green-to-near-infrared region, tobacco stems consistently reflect more light than leaves, giving the system a reliable spectral signature to work with. The Specim FX10e hyperspectral camera captures these variations in fine detail, while SpecimINSIGHT analyzes the data instantly to classify each pixel on the fly.
Additionally, even in complex mixed samples where leaves and stems appear nearly identical to the naked eye, the HSI system accurately mapped their locations. This capability to distinguish materials based on their spectral fingerprints enables automated, real-time sorting. As soon as the camera scans the tobacco, the software identifies and labels the stems and leaves, providing precise data that can direct an automated mechanical sorter for continuous, hands-free processing along the production line.
Improving Tobacco Quality Control with Automation
By introducing HSI into the tobacco material sorting process, manufacturers can achieve new levels of consistency, accuracy, and operational efficiency. The Specim FX10e integrated HSI system provides several key advantages:
- Non-contact, real-time inspection: The HSI system scans tobacco materials directly on the conveyor at full production speed without any physical contact. It instantly distinguishes stems from leaves in every frame.
- Accurate stem vs. leaf classification: Advanced machine-learning models analyze each materialâs unique spectral signature to accurately identify stems and leaves, ensuring precise categorization before subsequent processing.
- Consistent process control: Automated spectral analysis helps maintain the desired leaf-to-stem ratio, supporting uniform material quality and blend consistency throughout production.
- Reduced manual errors: Automation minimizes reliance on manual visual sorting, significantly reducing grading errors, labor requirements, and variability between operators â improving overall process efficiency.
- Integration-ready system: The HSI classification output can be seamlessly connected to actuators or sorting mechanisms on the production line, enabling easy integration into existing systems and supporting fully automated material sorting and separation for tobacco processing.
Specim Hyperspectral Imaging Solutions
Specim FX10 hyperspectral camera and SpecimINSIGHT
Specim, part of the Konica Minolta Group, is a global leader in HSI technology, providing advanced imaging solutions for industrial and research applications. With decades of expertise in spectral imaging, Specimâs technologies enable precise material identification, classification, and quality monitoring across a wide range of industries.
Beyond the Specim FX10e hyperspectral camera, Specim offers an extensive portfolio of hyperspectral solutions that cover multiple wavelength rangesâfrom visible and near-infrared (VNIR) to short-wave infrared (SWIR), mid-wave infrared (MWIR), and long-wave infrared (LWIR). These solutions include in-line and airborne hyperspectral systems, designed for applications such as agriculture, food quality and safety, pharmaceutical manufacturing, recycling, and industrial raw material inspection.
Interested in learning more about the Specim FX17e HSI system? Or looking to integrate HSI technology into your operations for smarter, data-driven quality control? Contact us today to discover how Konica Minolta Sensing and Specim can help enhance your production processes with HSI solutions.