In this research, a double-acting cylinder and a Programmable Logic Controller (PLC) are used to build and implement an automatic height-based object separator. By combining cutting-edge sensor technology for height detection with the actuation capabilities of a double-acting cylinder, this system automates the separation process, minimising errors and reducing reliance on manual labour. Its goal is to improve efficiency and accuracy in sorting objects of different heights in industrial environments. The process entails setting up the PLC to process data from height sensors, accept input, and adjust the actuation mechanism as necessary. According to experimental data, the system reliably sorts items with a high degree of dependability, demonstrating a significant improvement in separation efficiency. Potential solutions are addressed along with implementation challenges like response times and calibration. The results open the door for further advancements in industrial automation technology and highlight the value of automated systems for height-based sorting applications. By emphasizing the value of innovation in production process optimisation, this study adds to the expanding corpus of knowledge in automation and robotics. Using a non-contact sensor, a conveyor belt moves items to a detecting zone where their heights are determined. The PLC processes the sensor data and uses the object’s height to decide the proper action. The item is then physically separated onto the appropriate bin or conveyor belt by activating a double-acting cylinder.