The mealworm sorting machine from Taizy is a fully integrated automated separation system engineered for commercial mealworm farming operations. This automatic insect sorter combines three modular units—a main separator, secondary sorting unit, and optical color sorter—to deliver complete processing in one continuous workflow. Capable of handling 400–600 kg of fresh larvae per hour, or 500–700 kg of pre-dried mealworms with the color sorter attached, this tenebrio separator replaces labor-intensive manual sorting with precision automation.
Unlike basic screening equipment, this mealworm processing machine performs multiple separation tasks simultaneously: frass removal, skin and debris extraction, dust collection, size grading into large/medium/small larvae, and separation of pupae and dead insects from healthy stock. Variable frequency drives control both conveyor belt speed and fan airflow, allowing operators to fine-tune settings for different larval sizes and moisture conditions. The enclosed dust-proof design, quick-change mesh screens, and mobile configuration make this insect grading equipment suitable for small breeding farms and large commercial facilities alike.
What Functions Does a Mealworm Sorting Machine Have?
This machine integrates multiple functions into one system. The process flow is smooth and efficient, while a range of practical design features improve the overall operating experience.
Integrated Synchronous Operation
The machine follows a fully synchronized workflow. It is designed according to the logic of manure screening first, followed by skin removal and dust collection, and then mealworm sorting. It completes live mealworm grading, as well as separation of dead worms and pupae in one single process, without the need for secondary manual material handling.
Flexible Parameter Adjustment
All operating parameters can be freely adjusted. The speed of the dual-layer sorting belts and the airflow of the blower can be independently controlled. The mealworm grading section is equipped with a variable frequency system, making it suitable for different mealworm sizes and various sorting conditions.
Secondary Fine Sorting
The secondary sorting unit performs an additional screening process on the material. Lower-level mealworms are lifted and conveyed, while healthy mealworms are automatically returned to the main machine for re-grading. Pupae, dead worms, and impurities are uniformly conveyed to the color sorter.
Intelligent Color Sorting and Impurity Removal
The color sorter uses high-precision color sensors to accurately identify and remove black dead mealworms and various farming impurities, further improving the purity of the final product.
Enclosed Dust-Proof and Environmentally Friendly Design
The enclosed manure screening structure is equipped with dedicated collection bags. Mealworm skins and dust are all collected in a centralized manner, effectively suppressing dust emission and keeping the working environment clean and tidy.
Convenient Operation, Maintenance, and Mobility
The machine is designed for easy disassembly and maintenance. Manure screens and grading screens can be quickly removed and replaced. The dust-proof cover and control box of the main machine can be freely opened, allowing operators to observe machine operation status and perform routine maintenance conveniently. The system also features flexible site adaptability. The entire machine is equipped with swivel casters with brake functions, allowing it to be freely moved and fixed indoors without being restricted by workshop layout.
Suitable Materials
The Taizy Combined Mealworm Sorting Machine is mainly used for processing mixed mealworm materials. Suitable materials include large, medium, and small live mealworms at different growth stages, as well as mealworm manure, shed skins, pupae, naturally dead mealworms, and small amounts of farming impurities generated during the breeding process.
The machine is suitable for two major processing forms: fresh live mealworms and pre-dried mealworms. For raw materials containing vegetable leaves, fruit peels, and other materials that may easily cause blockage, the machine can be modified with an external blower to expand its material adaptability.
By replacing screens with different specifications, the machine can sort mealworms at all growth stages, from first-instar larvae to fully grown adult mealworms. This enables the equipment to cover the entire sorting process required for mealworm farming and primary processing operations.
Especificações técnicas
Main Separator
| Item | Especificação |
|---|---|
| Poder | 2.85 kW |
| Dimensões | 190 × 78 × 129 cm |
| Peso | 285 kg |
| Standard Mesh | Upper 26 mesh, Lower 3mm / 2mm aperture |
| Functions | Frass screening, skin removal, dust extraction, primary grading, initial pupae/dead insect separation |
Secondary Sorter
| Item | Especificação |
|---|---|
| Poder | 0.46 kW |
| Dimensões | 250 × 80 × 139 cm (max height) |
| Peso | 124 kg |
| Functions | Secondary grading, larval elevation, healthy insect recirculation, debris directional conveying |
Color Sorter
| Item | Especificação |
|---|---|
| Poder | 0.8 kW (air compressor required separately) |
| Dimensões | 100 × 40 × 110 cm |
| Peso | 45 kg |
| Functions | Color recognition, precision removal of black dead insects and impurities |
Combined System
| Item | Especificação |
|---|---|
| Total Power | 4.1–4.8 kW |
| Total Weight | 420 kg |
| Combined Dimensions | 5.1 × 0.8 × 1.28 m |
| Fornecimento de Energia | 220V / 50Hz single-phase |
Capacidade de Processamento
| Material Type | Configuration | Hourly Output |
|---|---|---|
| Fresh live larvae | Without color sorter | 400–600 kg/h (800–1000 jin/h) |
| Pre-dried mealworms | With color sorter | 500–700 kg/h (1000–1400 jin/h) |
Note: Small larvae, frass, and skin are excluded from output measurements.
Mechanical Structure of the Mealworm Sorting Machine
Main Components of the Mealworm Sorting Machine
| No. | Part Name (English) | No. | Part Name (English) | No. | Part Name (English) |
|---|---|---|---|---|---|
| 1 | Funil | 16 | Mealworm Sliding Plate | 31 | Main Roller Wheel |
| 2 | Upper Screen | 17 | Lower Screen Drive Wheel | 32 | Small Sliding Plate |
| 3 | Manure Discharge Box | 18 | Small Motor Drive Wheel | 33 | Brush Shaft Wheel |
| 4 | Machine Frame | 19 | Air Outlet Pipe | 34 | Escovar |
| 5 | Sorting Belt | 20 | Large Motor Main Shaft Wheel | 35 | Motor Wheel |
| 6 | Skin Collection Cover | 21 | Fixed Casters | 36 | Vibration Motor |
| 7 | Lower Screen | 22 | Variable Speed Motor | 37 | Vibration Unit Frame |
| 8 | Medium Mealworm Outlet | 23 | Large Motor | 38 | Spring |
| 9 | Small Mealworm Outlet | 24 | Small Motor | 39 | Secondary Unit Power Cable |
| 10 | Dust Collection Fan | 25 | Power Cable | 40 | Color Sorter Feeding Inlet |
| 11 | Swivel Casters | 26 | Main Machine Switch | 41 | Switch |
| 12 | Upper Screen Drive Shaft Wheel | 27 | Bag Support Frame | 42 | Color Sorter Healthy Mealworm Outlet |
| 13 | Variable Speed Motor Drive Wheel | 28 | Hopper Switch | 43 | Color Sorter Dead Mealworm Outlet |
| 14 | Sorting Belt Main Roller | 29 | Secondary Sorting Unit Frame | — | — |
| 15 | Brush Shaft Wheel | 30 | Large Sliding Plate | — | — |
How Does the Mealworm Sorting Machine Work?
Stage 1: Primary Separation (Main Unit)
Raw material enters the main separator where mesh screens remove frass and fine debris. Integrated fans extract shed skins and dust into collection bags. The dual-layer sorting belt separates larvae by size while preliminary separation distinguishes healthy larvae from pupae and dead insects.
Stage 2: Secondary Refinement (Secondary Unit)
Undersized or low-position larvae transfer to the secondary sorter for re-evaluation. Healthy specimens automatically return to the main unit for re-grading, while pupae, dead insects, and remaining debris convey toward the color sorter.
Stage 3: Optical Purification (Color Sorter)
High-precision color sensors identify and eject black dead larvae and residual impurities. This final purification step achieves over 99% separation accuracy under standard operating temperatures of 25°C and above.
What Are the Advantages of the TZ-6 Mealworm Sorting Machine?
Combined with the equipment structure, technical parameters, and real application scenarios, this product offers significant overall advantages.
Cost-Efficient Energy Consumption
The whole machine uses a standard 220V, 50Hz civil power supply. It can be installed and used in ordinary farms without modifying the existing electrical system.
The power configuration is as follows:
- Main machine power: 2.85 kW
- Secondary sorting unit power: 0.46 kW
- Color sorter power: 0.8 kW
- Total power: 4.1–4.8 kW
The energy consumption is reasonable and efficient.
The machine should be equipped with a 6 mm² national standard copper core cable and a dedicated switch or socket rated at 20A or above to ensure safe operation. The socket, power supply voltage, and other electrical requirements can also be customized according to customer needs.
Stable Operation
The main machine weighs 285 kg, the secondary sorting unit weighs 124 kg, and the color sorter weighs 45 kg, giving the complete system a total weight of 420 kg.
The structure is made of solid materials, ensuring low vibration and stable operation during use, with minimal risk of displacement.
Each unit is reasonably designed in size. After assembly, the total machine length is 5.1 meters, which allows easy placement in standard farming workshops.
High Sorting Accuracy
Through three-stage processing—primary screening by the main machine, secondary sorting by the secondary unit, and intelligent removal by the color sorter—the machine achieves a sorting purity rate of over 99% under standard operating conditions at 25°C and above.
It can accurately separate healthy live mealworms, dead worms, pupae, and impurities.
Flexible Combination Options
Users can freely configure the equipment according to production requirements:
- Using only the main machine + secondary sorting unit allows completion of the basic full sorting process
- Adding the color sorter enables complete separation of dead worms and impurities, meeting high-end product processing standards
Wide Adaptability Range
The machine is equipped with multiple standard screen types. Different mesh sizes and apertures can be replaced according to demand, making it suitable for mealworms at different growth stages.
It also supports external blower modification, which helps solve clogging issues caused by raw materials containing high levels of impurities.
Simple Operation
The speed controller and frequency converter layout is clear and easy to understand. Operators can master the machine after short-term training.
Common issues such as sorting belt deviation and screen replacement are handled with standardized solutions, making daily operation easy and worry-free.
Why Choose Taizy Mealworm Sorting Machine?
Certifications
| Certification | Standard |
|---|---|
| Quality Management | ISO9001 |
| Safety Standard | CE |
| Inspection | SGS / TUV |
Power Requirement
| Item | Especificação |
|---|---|
| Tensão | 220V / 50Hz |
| Poder | 4.1–4.8 kW |
| Wiring | 6mm² copper wire |
| Circuit | Dedicated 20A breaker + grounding |
Service & Support
- 1-year warranty
- Remote video support
- Installation guidance
- Spare parts supply
- Optional on-site commissioning
Perguntas frequentes
Can the machine be integrated into an existing mealworm production line?
Yes. The system is designed with modular input and output interfaces, allowing it to be connected directly to existing feeding conveyors, drying systems, or packaging lines without major structural modifications.
What is the expected lifespan of the machine under continuous operation?
Under normal commercial usage and routine maintenance, the main structure typically lasts 8–10 years. Wear parts such as mesh screens, belts, and fans are consumables and may require periodic replacement depending on processing intensity.
How often does the machine require cleaning during daily operation?
For high-volume farms, cleaning is generally recommended every 8–12 hours of continuous operation, especially for mesh screens and dust collection units to maintain consistent airflow and separation efficiency.
Can the sorting accuracy be affected by humidity or temperature changes?
Yes, environmental conditions can influence performance. High humidity may increase adhesion between larvae and debris, while low temperatures can reduce larval activity. Stable conditions between 20–30°C and controlled humidity yield optimal results.
What level of operator training is required?
Basic operation training is sufficient. Most operators can learn feeding, parameter adjustment, and cleaning procedures within 1–2 days. No specialized mechanical or electrical background is required.
Can the machine handle mixed insect species or only Tenebrio molitor?
The system is primarily optimized for Tenebrio molitor (mealworms). While it may process similar-sized larvae, separation accuracy may decrease for mixed species without parameter recalibration and test runs.
How is product quality consistency ensured across different batches?
Consistency is maintained through adjustable frequency control systems and standardized mesh configurations, ensuring stable grading even when raw material size distribution varies between batches.
What happens if foreign objects like small stones or metal enter the system?
Small non-organic contaminants are typically removed in early screening stages. However, installing a pre-cleaning or magnetic separation unit is recommended for heavily contaminated raw materials to protect internal components.
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