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POTATO PROCESSING I N T E R N A T I O N A L Supporting the potato industry worldwide Issue 2 • Volume 28 • 2020 Products Spotlight – Robotization Markets - Eastern Europe Cashing In and Smart Packaging Potato Chips Will Experience with Chips Consider a Greener Future Moderate Growth PB visit potatobusiness.com incorporating our digital magazine
22 38
Contents
4 Comment 34 Markets - Eastern Europe
What Will Smart Packaging Be Like in the Future? Potato Chips Will Experience Moderate Growth
6 News 38 Process: Seasoning and Coating
Latest Industry News The Market Provides Equipment for Every Need
12 Showtime – Europatat Congress 42 Products - Chips
A New Age for Potatoes Cashing in with Chips
16 Process - Drying 46 Exclusive Interview - The Little
Keeping an Eye on Water Evaporation Potato Company
“Organic Means Growing Responsibly”
20 Expert View - Bühler Aeroglide
Lab Testing for Drying Success 50 Exclusive Interview – Belpotato
Sustainability High on the Agenda for New Belgian
22 Process - Sorting Branch Organization
Identifying Foreign Material with the Latest Technology
54 Storage Special
26 Expert View - Tomra Food Reasons Why Energy Efficiency Is Important
Welcome to The Optical Sorting Revolution
56 Storage Management
30 Spotlight - Keeping an Eye on Everything
Robotization and Smart Packaging
Consider a Greener Future
42 46
50
What Will Smart
Packaging Be Like
in the Future?
Dan Orehov - Managing Editor
email: dan.orehov@trade.media, Skype: dan.orehov
F To achieve higher
rom my talks with various detectors and date coders. This
industry experts and allows operators to control a
equipment manufacturers, levels of automation complete system from a single,
one thing same thing with intuitive User Interface (UI) to
reiterates: the future of packaging is in their packaging promote greater productivity,
undoubtedly digital, and that’s where lines customers are reliability and serviceability.
anyone can see some of the most As for plastic, while right now it is still
interesting developments recently. using technologies essential, it is important not to view
Food manufacturers are facing
numerous challenges; from ensuring
such as the Internet it as a standalone solution to the
world’s sustainability challenges.
their operations are as energy of Things (IoT), self- Sourcing material from sustainable
efficient as possible and striving for suppliers, applying eco-friendly
the lowest possible carbon footprint,
learning software practices in manufacturing and
to delivering transparent solutions – and artificial finding innovative ways of reducing
all while meeting consumer demand carbon footprint are additional ways
for relevant experiences, real-time intelligence (AI). in which manufacturers can improve
interaction and personalized content. their sustainability credentials.
This means that packaging systems with higher levels of The industry is constantly evolving to find new energy-
automation and improved diagnostics are in growing saving solutions, such as power-saving software for food
demand. processing and packaging lines. Such developments help
To achieve higher levels of automation in their packaging brand owners reduce carbon footprint and energy usage
lines and for increasing machine up-time and therefore the by offering features that include ‘stand-by time’.
economic efficiency of operations, customers are using What measures does your company undertake to be more
technologies such as the Internet of Things (IoT), self- sustainable and environment-friendly in terms of the
learning software and artificial intelligence (AI). The latest in packaging equipment and materials you use?
packaging equipment can streamline all components of
the packaging line, including multi-head weighers, metal Stay safe! l
Dan Orehov (managing editor) Nicoleta Marasescu
email: dan.orehov@trade.media (managing director) Like our page and join our online community:
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Tel: +40 770 951 871 nicoleta.marasescu@trade.media
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Follow us on Twitter: http://twitter.com/potatobusiness
Skype: nicoleta.marasescu We will update regularly on our activities, upcoming
Tudor Vintiloiu (web & digital editor) features and show attendance.
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Tel: +40 721 277 042 Jonathan Thomas, Cedric Porter, Join our group on LinkedIn search for: PPI News
Skype: tudor.vintiloiu Nora Olsen, Mintel Group LTD,
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News
Tolsma-Grisnich
Reveals New Storage Projects last few years to become a successful
T
olsma-Grisnich recently outside air is also possible. All QCCs and place for storage and grading. The storage
announced the delivery of a QMLs are controlled by a Vision Control facility has a 2,100 tons capacity for the
brand-new storage and grading climate computer. The grading installation cooling of seed and processing potatoes
line, designed for one of the features a roller inspection table, the and is climate-controlled. The potatoes
biggest potatoes and grains wholesale MV13 grading machine and buffer-bins are stored in boxes. The Vision Control
production companies in the Bryansk with integrated box-fillers. The grader storage computer saves data such as
region, in Russia. The storage and grading contains four sieving decks, which sort temperature, relative air humidity and
line have the capacity to handle over out three different sizes of potatoes. The CO2 and ensures the storage is
6.000 tons of seed potatoes. The building box filler starts automatically after sensing permanently monitored. The units are
of this new seed potato business in Russia the box in its place. The total hourly infeed designed to run in an energy efficient
began in early 2019, and the completed capacity is 30 tons of potatoes per hour, manner, to keep the power bill low.
operation includes storage locations for and the fully automated process ensures a Both the Quadro Air Mix Unit 60 (QML
boxed potatoes, as well as a fully- significant reduction in the amount of 60) and the Quadro Compact Cooler are
equipped grading hall. Four storage labor required. characterized by their high efficiency
facilities have been equipped with the At the same time, the company revealed and easy installation. The QML can be
latest QCC 60 and QML 60 compact the completion of another storage facility connected to a cooling unit and the
coolers. Each cell has a capacity of 1,500 in the heart of Rakaia, Timaru, New QCC achieves different cooling
tons of boxed potatoes. The QCCs are Zealand. The beneficiary is the Rakaia Hub capacities, using the variable control on
fitted with a hatch, so that ventilation with Ltd, a company that has grown over the the compressor.
Japan’s Calbee Buys Haith Appoints
Sweet Potato Processor Financial Controller
C P
albee, Inc. announced in a press release that it has reached The designer and manufacturer of vegetable
a definitive agreement for the purchase of stocks with J- handling equipment has appointed a new financial
GIA I Limited Partnership, which was founded by Japan controller to head up its accounts department. Emma
Growth Investments Alliance, Inc. and are individual Johnson joined Haith Group last month, reporting to
shareholders of Nigel Haith, managing director. With nine years of financial
Potato Kaitsuka experience gained at an industrial hose manufacturer, Emma
Co. Ltd. has been given responsibility for managing all aspects of
Under the long- Haith finances, dealing with day-to-day financial
term vision administration as well as producing monthly accounts,
announced in May forecasting and budget management.
2019, Calbee aims Emma Johnson is pleased to be joining the company at an
to establish exciting period. “Haith is well known and is synonymous with
overseas markets and new food domains as growth pillars. The entry excellence in the farming sector. I’ve only been here a few
into the sweet potato business by making Potato Kaitsuka a weeks, but it is clear that the company is growing. As the team
subsidiary will strengthen their efforts to enter new food markets. here focuses on meeting the increasing demand, we need to
Potato Kaitsuka started operation in 1967 as a wholesale company ensure the financial side of the
specializing in sweet potatoes. Today, based mainly on their original business runs as smoothly and
brand of sweet potato, “Beni-Tenshi”, they engage in the sale of raw effectively as possible. I’m looking
materials for baked sweet potato to retail stores, as well as the direct forward to working with the accounts
sales of baked sweet potatoes. With the demand for sweet potatoes team to ensure this continues.”
expanding due to the introduction and utilization of baking potato Incorporated as a limited company in
machines in retail stores, the amount of exports is also increasing in 1964, Tickhill Engineering, which trades
recent years, thanks to the rising recognition of baked sweet potato as Haith, has a long tradition of
products in Greater China and South Asia. The Ibaraki Prefecture, innovating vegetable handling. The
where Potato Kaitsuka is located, ranks second in terms of domestic company invented the modern barrel
sweet potato yields in 2018, and Potato Kaitsuka has a considerable washer in 1961, developed the brush
share of this production. roller bed in the 1970s, which was
While the acquisition of shares has no impact on consolidated superseded in the ’80s by the Hydro
results for the year ending March 31, 2020, the acquisition will Flow washer. The company introduced
contribute to improving the performance of Calbee Group over the the Self Clean washer at the beginning
medium- to long-term. of this century.
6 Issue 2/2020 • POTATO PROCESSING
News
Key Technology Promotes
Quentin Kemph
high-performance digital sorting, to that, Service Technician and
conveying and other automation Precision Welder/Supervisor. Innovative
systems to customers that process problem solving has led Kemph to
fruits, vegetables, potatoes, nuts, snack develop five patents at Key.
foods, poultry and more. “As I pivot my career to become more
Quentin Kemph has been with Key for directly involved with customers, I’ll
more than 30 years, holding a variety of continue to be available to our
positions of increasing responsibility. applications and technical support
Most recently, he was Sales and teams, as needed,” said Kemph.
K
ey Technology, a member of Applications Technical Support Prior to Kemph’s appointment, Jeff
the Duravant family of Specialist where he worked closely with Nielsen was responsible for Key sales in
operating companies, customers and Key teams to customize both the Southeast and South-Central
announced the promotion of equipment that improves product United States. To better serve this large
Quentin Kemph as Area Sales Manager quality, increases yield and reduces 12-state area, Nielsen will now focus on
for the South-Central United States. operating costs. Previously, he was the Southeast territory as Kemph takes
Kemph is responsible for bringing Key’s Senior Applications Specialist and prior on the South-Central region.
tna Launches Latest robag 3
Packaging Series
t
na will showcase its range of integrated, start-to-finish food “The food packaging industry is evolving
processing and packaging solutions for the snack industry at a rapid pace, with manufacturers
at this year’s SNAXPO - including the newest addition to the finding themselves under ever-increasing
tna robag® 3 packaging portfolio, the tna robag® 3e. Visitors pressure to improve the operational
are also invited to experience live demonstrations of the tna efficiency of their packaging processes. In
intelli-flav® OMS 5.1 on-machine seasoning system, the tna an industry where the real and virtual
roflo® HM 3 horizontal motion and tna roflo® VM 3 vibratory worlds are increasingly converging, digital
motion conveyors - suitable for a range of snack applications, control systems must become more
from potato chips and pellets, to french fries. The new tna sophisticated to deliver the levels of
robag® 3e will take centre stage at their booth at the 2020 automation and performance expected -
SNAXPO trade show. With fully integrated real-time from a single piece of equipment to entire
communication software and smart diagnostics, the system production lines,” comments Steven Wolfe,
focuses and delivers on control sophistication. general manager at tna North America.”
Tong Engineering Upgrades Coil Cleaner
V
egetable of root crops including potatoes, carrots, parsnips, onions and
handling more,” says Richard Knighton, sales manager at Tong Engineering.
equipment He adds that “with reduced downtime and maximum efficiency
manufacturer, remaining at the forefront of equipment upgrade decisions, the
Tong Engineering, is new super-speed self-cleaning function on the latest models is
building upon the success already proving to bring invaluable time-saving and operational
of its popular potato and benefits.”
vegetable coil cleaning Incorporating a heavy duty, scissor-action shaft design, the
unit, with new deformable PU coil shafts feature an easy-maintenance coupling
advancements for and are fully adjustable to suit a wide range of sizing
optimum performance and requirements. With a direct-drive motor on every shaft, the coil
ease of maintenance. Tong’s cleaning and sizing unit is not only easy to maintain, but also
range of coil cleaning and ensures maximum energy efficiency during operation. The next
pre-grading systems are designed to offer gentle handling of crop generation coil cleaner from Tong can be built to suit all
while combining soil removal and crop sizing within one unit. throughput and sizing requirements, available in 4, 6 and 8 row
“Our PU coil cleaner is a very popular choice among growers and configurations as standard, and is popularly combined with Tong’s
processors, offering very flexible application across a wide variety EasyClean separator for efficient cleaning and sizing results.
8 Issue 2/2020 • POTATO PROCESSING
News
J.R. Simplot and McCain Foods
in Patent Legal Battle
J
.R. Simplot and McCain Foods have of a high electric field directly to the that while the claimed process employs a
spent the last few years battling in vegetables and/or fruit under conditions well-known natural phenomenon, it does
the U.S. District Court for the District such that the resulting increase in the not preempt the use of the phenomena.
of Idaho, over issues concerning a temperature of the vegetables and/or fruit Instead, the claim only seeks to foreclose
design patent related to a spiraled potato. is almost zero or at least sufficiently low as the use of the phenomenon “in conjunc-
The challenge refers to McCain’s utility to not amount to a preheating step.” tion with all of the other steps of the
patent that is directed to the process of Simplot argued that vegetables softening claimed process.” Simplot also argued that
using high-energy electric field technology (i.e., becoming easier to cut) when exposed the claim is directed to an abstract idea. It
to pretreat potatoes (and other vegetables) to an electric field is a natural law and, reasoned that softening vegetables before
before cutting and cooking them. Simplot therefore, a patent directed to an electric cutting and cooking is a vague idea, so
filed a motion for judgment on the field making vegetables easier to cut is not there must be some inventive concept for
pleadings, arguing that McCain’s patent is patent eligible. In Simplot’s view, claim 1 is the patent to survive. The court, again,
ineligible because it contains an overbroad impermissibly directed at the natural law disagreed. It said the inventors recognized
claim directed to both a natural law and an itself. The court, however, noted that while that applying an electric field to vegetables
abstract idea: that vegetables soften when it is true that Section 101 prohibits patents would soften them, but that’s not what
exposed to an electric field. Claim 1 of the based on laws of nature, a claim drawn to a they patented. Their patent claims an
asserted patent reads: “A process for law of nature or natural phenomena does application of that knowledge to create a
treating vegetables and fruit before not become nonstatutory simply because new process. The court found the asserted
cooking in order to reduce their resistance it contains a law of nature. Looking at Rapid claim patent eligible and denied the
to cutting, characterized by the application Litigation v. CellzDirect, the court stated motion for judgment on the pleadings.
Burts Potato Chips Patatas Meléndez
Secures Growth Acquires Integral Potato
Through Costa Coffee
P
atatas Meléndez recently announced the purchase
of the Integral Potato facilities, located in the
Valladolid town of Medina del Campo, Spain, which
O
ne of UK’s leading
was declared bankrupt by the Commercial Court of
independent snacking
Valladolid in November 2017 and which began liquidation
companies has marked the
procedures in November 2019. The purchase agreement,
next stage in its growth
authorized by the bankruptcy judge, states that in addition
towards GBP100m worth of sales by
to the acquisition of the tangible assets of the bankrupt
2022, announcing nationwide
company and the payment of a significant amount towards
distribution of Burts Potato Chips
reducing its liabilities, the company must retain the
through the Costa Coffee chain.
workforce of Integral Potato. The aforementioned operation
According to retailtimes.co.uk, Burts
authorized by the Commercial Court has also allowed
Snacks has revealed the new listing
Patatas Meléndez to acquire the ownership of the land in
following its GBP7m investment into the
which Integral Potato was carrying out its activity. The
business last year. This aided the
purchase of the Integral Potato factory is part of the growth
introduction of a range of new frying and
and innovation strategy of Patatas Meléndez, who will make
popping techniques across its two manufacturing facilities, helping
a significant investment
Burts to satisfy increasing demand for its unique products. The
in the new facilities
Plymouth and Leicester based business forecasts sales of GBP54.3m
acquired, in a clear
by the end of this financial year, as it continues to outperform in the
commitment to social
chips, snacks and nuts category. Burts Snacks’ top-selling hand cooked
cohesion in the Medina
chips, Burts Potato Chips, will be available in four flavors – Sea Salt, Sea
del Campo region.
Salt & Malted Vinegar, Mature Cheddar & Spring Onion and Sweet
Patatas Meléndez is the
Chilli – at Costa Coffee stores across the UK from March 2020.
leading Valladolid
Simon Knight, sales & marketing director at Burts Snacks, commented:
company in the
Eric Tavoukdijan, commercial marketing director at Costa Coffee,
production of fresh
added: “At Costa Coffee, we’re passionate about providing our
potatoes in Spain with
customers with the highest quality produce and are constantly on the
a 19.1% market share
lookout for innovative products from provenance-based, authentic
and a turnover of
brands, that will appeal to everyone who walks through our doors.”
over EUR88m.
10 Issue 2/2020 • POTATO PROCESSINGShowtime – Europatat Congress
A New
Age for
Potatoes
In anticipation of this year’s
edition of the Europatat
Congress, I talked to Raquel
Izquierdo de Santiago,
managing director of the
European Potato Trade
Association about the most
pressing issues of the industry
today, as well as about the
upcoming congress.
By Dan Orehov
What should participants look Association during the meetings of potatoes" with the key word of the
forward to, at the upcoming the various Europatat Commissions day being digitalization. With this
Europatat Congress this year? (seed potatoes, early and ware topic, we want to convey to the
The Europatat Congress has become potatoes, packers, technical and sector, our members and
a key gathering for all potato regulatory issues and RUCIP). These participants, that digitalization is not
professionals on the edge of a new sessions will also feature different only a business buzzword, but that
potato season. Under the title “A new guest speakers. digital technologies have the
age for potatoes”, this year’s potential to help tackle important
Congress will explore the Which are the main topics for economic, social, climate and
possibilities and barriers to discussion that you have prepared environmental challenges facing the
successfully make the most of and what determined you to EU's agri-food sector, while offering a
digitalization in the potato sector. choose these themes? huge advantage for companies,
Key speakers from both the business This year’s event will be organized including those in the potato sector.
and the European institutions will around the theme "A new age for High-tech and digital solutions are
share with the audience their
insights on the benefits for
sustainability and the economic “Europatat, together with the relevant
potential that digitalization can offer
to companies. Besides the bodies in Belgium, France and Ireland,
professional working program, our
Congress will also offer plenty of have launched a promotion campaign to
opportunities for networking, such
as the exclusive Cocktail & Gala put fresh potatoes back in the minds and
Dinner that will take place at the
beautiful BELvue Museum with a
lives of millennials, under the title
view over the gardens of the Royal “Potatoes, prepare to be surprised –
Palace. In addition, Europatat
members will have the chance to Europe’s favorite since 1536.”
review the different activities of the
12 Issue 2/2020 • POTATO PROCESSINGShowtime – Europatat Congress
gaining ground not only at the
producer level but also along the
whole supply chain. The use of “Potato traders and packers are
digital technologies and big data
throughout the potato chain can
improving skills machine-operators to
have a huge potential to mitigate limit packaging losses, as well as choosing
increases in environmental costs
stemming from higher standards. In optimal packaging materials that preserve
our view, research and innovation is
one of the key drivers to enhance the quality of potatoes while reducing the
competitiveness along the whole
food supply chain, and it is also an amount of plastic used.”
important factor in generational
renewal, particularly in agriculture. currently traded, and that the EU-27 European policy and regulatory
Future research should help operators do not loose framework for sustainable food
producers to apply digital and competitiveness in the UK and systems should be developed to face
innovative instruments such as international markets. For this all these challenges and to achieve a
remote sensing applications and reason, Europatat has sent a position sustainable food system.
artificial intelligence technologies on paper to the EU-UK negotiation team
their farms and crops. of the European Commission on What initiatives are in place, or
Even though one of the main which the sector calls on the EU to will be introduced in the coming
priorities of the new European make a priority the amendment of years, with regards to creating a
Commission is to achieve a digital current EU legislation in order to more sustainable potato
transformation for all the sectors of include the UK as one of the third industry, supply chain and come
the economy including agriculture, countries from which the EU can up with solutions that help
there are still significant gaps in the import seed and ware potatoes. reduce food waste.
knowledge, applications and The European potato sector is
perceptions around these What are the current already contributing to the
technologies that need to be challenges, facing the European sustainability of the supply chain and
addressed. Therefore, digital potato industry at present, the transition to a circular economy,
education for agri-food businesses besides Brexit? which includes the reduction of food
must be a key component of the EU’s The concern regarding food waste. Potato traders have already
strategy for the upcoming years. sustainability along the whole put in place specific strategies to
supply chain has been increasing in reduce both the generation of
Please discuss Brexit and the the political agenda in the past years. potato waste and the environmental
impact this can have on the entire There is a need to secure a fair, impact of their commercial activities.
European potato industry. healthy and environmentally-friendly For instance, breeding companies
Europatat members are highly food system, a message that the are constantly involved in the
concerned by the future of trade in potato sector fully endorses. In this research of new potato varieties with
potatoes between Member States of sense, our sector is already taking higher yields and less susceptible for
the EU-27 and the UK. The UK responsibility towards relevant EU diseases and defects. Potato traders
imports annually about 255.000 tons ambitions such as a better and packers are, for example,
(EUR 112 million) of fresh or seed management and reduction of improving skills machine-operators
potatoes, of which around 191.000 chemical plant protection products; to limit packaging losses as well as
tons (EUR 84 million) are from the reduction of plastic packaging while choosing optimal packaging
EU-27 countries. The largest ensuring that no food waste is materials that preserve the quality of
proportion of UK imports are by far generated; promotion of sustainable potatoes while reducing the amount
the frozen products, such as frozen food consumption; or the transition of plastic used. The potato sector is
chips, which are not counted for towards a more sustainable storage also jointly creating alternative range
above and come entirely from the and transport. options for out of size potatoes.
EU-27. Regarding UK exports of Research and innovation can provide
potatoes, these concern mostly seed solutions for sustainable food How do you believe the ban of
potatoes, and almost 70% in volume systems and market opportunities. CIPC will impact the European
(around 205.000 tons) and over 60% For instance, new technologies such potato industry?
of value (around EUR 84 million) is as new plant breeding techniques The European potato sector is
sent to the EU-27 countries. can contribute to various goals of indeed facing a major challenge. On
Therefore, it is of outmost the European Union by saving land the one hand, it is important to
importance for our sector that the resources and reducing crop prevent possible cross-
negotiations result in securing the protection products while stabilizing contamination of potatoes that are
most stable situation as possible on and increasing crop yields to provide stored or transported in installations
what refers to volumes and values food security. However, a coherent that used to work with CIPC. On the
POTATO PROCESSING • Issue 2/2020 13Showtime – Europatat Congress
with young families). Under the title
“Potatoes, prepare to be surprised –
Europe’s favorite since 1536”, the
joint initiative, which is co-financed
by the European Commission under
the EU Promotion policy, has just
started and will run until December
2022. Young consumers in other EU
countries will also be reached thanks
to the translation of recipes into
Italian, German, Spanish and Polish.
The campaign’s backbone will be
Instagram and a common website,
but other social media channels such
as Facebook, Pinterest or YouTube
will be also used to provide tips and
tricks on how to easily integrate
potatoes into millennials’ daily
lifestyle. The message of the
campaign will be clear: potatoes fit
other hand, it is also important to campaign to put fresh potatoes back in a modern, healthy and sustainable
gain knowledge of the use of in the minds and lives of millennials lifestyle of millennials, because they
alternative means. Besides proper (people between 18 and 34 year old are a tasty, versatile and have good
cleaning practices, many storage living on their own, co-habiting or nutritional and health benefits! l
facilities will most likely also have to
be modernized in order to make use
of alternative means possible.
In cooperation with various umbrella
organizations in the supply chain at
European level, Europatat has been
very involved in the exchange of
knowledge and input to have a
workable future strategy. We are now
awaiting further information from
the European Commission regarding
a temporary MRL and a protocol of
sampling and cleaning that should
allow growers, trade and processing
to store and market potatoes
without risk and provided that they
do not longer use CIPC.
What initiatives are you taking or
will be taking, in order to raise
awareness of the benefits of
potato consumption among all
generations, especially the
young adults?
“Europatat members are highly concerned
Fresh potatoes remain Europe's most by the future of trade in potatoes between
popular main meal carbohydrate
and are deeply anchored in the food Member States of the EU-27 and the UK.
habits of the European Union,
however nowadays they face two Therefore, it is of outmost importance for
main obstacles: a long-term
decrease in their consumption; and a our sector that the negotiations result in
stagnation of their image as a
traditional food. To slow down this
securing the most stable situation as
consumption trend, Europatat, possible on what refers to volumes and
together with the relevant bodies in
Belgium (Flanders), France and values currently traded. ”
Ireland, have launched a promotion
14 Issue 2/2020 • POTATO PROCESSINGProcess – Drying
Keeping an Eye on
Water Evaporation
The main challenge with the drying process is the time required for starting and stopping
the process, mainly on larger dryers, in view of the required stabilization of the drying
process during these phases.
By Dan Orehov
T
he fast migration of water water depends on the heat input to the desired uniform moisture profile
during the drying process is the potato mash, the temperature of in combination with a high output.
most important to achieve the potato mash fed to the dryer, “The Andritz dryers enable a fast
a highly efficient drying the consistency of the potato mash filling and controlled emptying of
process. By creating a thin layer on and the exposure of the potato the dryers by which off-spec
the drying surface of a drying mash to the air that need to absorb product, that has to be sent to
drum, the water migration can be and evacuate the moisture, as well waste, is kept to an absolute
fast and homogeneous. By the as the condition of that air, its minimum,” says Alexander de Jager,
equal thermal treatment of the temperature, velocity and humidity. Industry manager at ANDRITZ
product, the final dry product has The boundary layer of saturated Gouda B.V. “Our main focus in potato
an extreme low water activity, vapor above the product layer being processing is on key equipment for
which inhibits the bacterial growth dried inhibits further evaporation the production of final consumer
during storage. By this aspect, the and therefore this boundary layer products, such as dryers and milling
drum dryer process is unique and will need to be broken to create the equipment to produce flakes and
not comparable by any other condition for further evaporation of granules, and the processing of
drying process. The equal the potato mash. In order to achieve potatoes for the production of a
treatment also ensures a lump free a uniform moisture profile, the wide range of modified starches and
instant product at reconstitution, density and film thickness must be derivatives. But what needs to
comparable with fresh prepared uniform over the width of the dyer, mentioned here as well is that
potato puree in appearance, as well as the condition of the Andritz not only provides dryers for
consistency and taste. surrounding air. A well distributed certain applications, but also
flow of fresh air supply will need to provides complete system solutions
BALANCING THE be balanced with the water vapor covering also up- and downstream
AIR FLOW DISTRIBUTION containing air being extracted. After processes such as sedimentation,
According to representatives from evaporation of the almost dry film is centrifugation, filtration, and
Andritz Gouda, the evaporation of an important aspect for obtaining solidification,” the added.
16 Issue 2/2020 • POTATO PROCESSINGProcess – Drying
FOCUSING ON SAVING
RESOURCES “A high rate of moisture removal depends
Effective drying is obtained by
using saturated steam. The new on a good heat transfer of the energy of
generation steam boilers are
capable of using alternative fuel, the steam inside the drum to the outside
like biomass, that often is
available from the production surface temperature. In addition, a good
plants operating the steam heated
dryers. Other methods of drying
evaporation area is needed, which is
can be considered in the near
future, such as electrical heating
reached by means of the extremely large
and induction heating. The surface of the drum.”
knowledge about various drying
and thermal treatment Dustin Dwight Tummers
technologies within Andritz, such
as in the Separation and Pulp &
Paper business areas, creates a
platform for further innovation on
drum technology, the company
says. By extraction of heat from
the continuous vapor flow,
heating of the required process air
can be realized, thus creating a
more efficient drying process.
Compact mechanical-electrical
drives make it possible to replace
air driven machine elements.
When high pressure cleaning is
applied, this can cause aerosol
contamination in the surrounding
area and creates high risk of
bacterial growth in a high hygiene
zone. Food producers that
recognize this risk apply dry
cleaning and only perform
fumigation once or twice per year.
When an atmospheric drum dryer sensors to ensure product of a CONSISTENCY
will be totally enclosed and constant quality, i.e. density, film IS A CHALLENGE
designed for CIP with smooth (flake) thickness and residual One of the main issues mentioned
surfaces and heated walls, as the moisture. Automation of pre- by the companies contacted for this
Andritz vacuum drum dryers, a CIP heating, start-up and shut-down article is the challenge to produce a
procedure will be possible in the procedures are minimum consistent flake quality at the
future, making the cleaning requirements, are already realized highest possible capacity. With
activities operator independent. As today with Metris addIQ control years of experience and lab drum
potatoes are more and more used systems from Andritz. In relation to trials, Tummers has developed the
in other food products, like baby this the constant quality of the perfect drum to make this
food, the need for adapting the potato mash is to be monitored for combination work.
production environment and anticipating on the machine “A high rate of moisture removal
production regime will move setting to realize an optimum depends on a good heat transfer of
along, such as the need to output. In a modern dryer, the the energy of the steam inside the
introduce barriers and access locks machine condition is monitored to drum to the outside surface
for entrance to a pressurized maximize uptime and predict the temperature. In addition, a good
drying room. necessary service intervals to evaporation area is needed, which
Alexander de Jager also says that maintain output and quality of is reached by means of the
an enclosed drum dryer product, as well as an interrupted extremely large surface of the
installation with defined production during the life time drum,” says Dustin Dwight
boundaries of the drying process cycle of the dryer. Lastly, in view of Tummers, marketing specialist at
will require full automation to the increasing demand for potato Tummers Food Processing Solutions.
control all required adjustments flakes, the demand for more On the other hand, there is a
based on strategically positioned efficient dryers is inevitable. defined balance between running
POTATO PROCESSING • Issue 2/2020 17Process – Drying
high capacity and high quality,
which often counter each other.
Based on long years of experience
and our in-house laboratory drum
trials, we have found the perfect
balance between these two
features,” he adds.
Improving the heat transfer factor
of the drum has enabled Tummers
to run at lower steam pressures,
which is more sustainable. And
they have improved the
condensate return system, allowing
better usage of the valuable energy
which is still in the condensate.
Furthermore, the focus of
innovation is on capacity and
hygiene, which is why the by 10% and substantially transfer. This combination allows
company has increased the size of improved the capacity per square processors to make a significant
their market leading flake drum meter, by improving the heat step up in producing higher
capacities on a single drum. The
other improvement aspect of
Tummers’ flake drum is hygiene,
with food safety as the main
driver, but also enabling longer
times between cleaning stops,
which further increases the yearly
line production.
“The side shields of the applicator
rolls generally have some leakage,
which is a point for regular
cleaning. Tummers has developed
an innovative new side shield,
which is greatly reducing this
leakage. Other areas of
improvement on the new drum are
the cleanability of the so called
back shield, the autotrax and the
vapor hood,” says Dustin Tummers,
adding that “rinse in place is a nice
feature, which is incorporated in
the new design, but the main
focus in our development was to
reduce build-up of contamination.
“Our main focus in potato processing With typical cleaning intervals of
is on key equipment for the production three to four months, it’s more
economic to extend these intervals
of final consumer products, such as then to shorten the cleaning stop
by a few hours.”
dryers and milling equipment to To conclude, depending on the
production volume and dry solids
produce flakes and granules, and the content of the feed, several dryer
sizes are possible. However,
processing of potatoes for the mechanical restrictions do not
production of a wide range of modified allow a production rate higher
than 1,000kg of dry product per
starches and derivatives.” hour. Lastly, aerosol contamination
needs to be eliminated during the
Alexander de Jager, Industry manager drying process, which remains one
at Andritz Gouda B.V. of the most important steps in
potato processing. l
18 Issue 2/2020 • POTATO PROCESSINGExpert View - Bühler Aeroglide
Lab Testing for
Drying Success Aldo De Tuoni
The drying step is key to achieving a high-quality product for a variety of process industries.
It is of vital importance to keep processing on a uniform and optimized regime for most of
the time, maintaining precise parameters needed to achieve a target moisture.
By Aldo De Tuoni, PE, CEM, senior process engineer serving food, feed and
industrial markets.
“For food applications, tests that consider
food safety are paramount. Drying,
E
xtreme process variations
have the potential to impact
the safety and the reliability of roasting, heating, toasting and
the process line, as well as the
profitability of a company. Drying tempering, can have a direct impact on
tests can be a path to success. food stability. In many cases, a thermal
PICKING THE RIGHT SOLUTION process acts as kill step destroying
When choosing simple process
equipment, such as a pump or a fan, it potentially harmful microorganisms.”
is only necessary to know some
20 Issue 2/2020 • POTATO PROCESSINGExpert View - Bühler Aeroglide
pressure and flow requirements in
order to select the right model from a “Laboratory testing helps identify
manufacturer’s catalog. But the
selection process is far more processing challenges and the
complicated with thermal processing
equipment because there are appropriate technology. For instance, if
multiple ways to introduce a product
to hot air. Combined with an infinite product sticks to the dryer surface,
array of products and processes that
depend on thermal processing, along
clumps, becomes brittle and breaks, or
with their different forms and sizes,
finding correlations or empirical
produces fine dust, testing will enable the
equations for every situation is drying manufacturer to design a drying
extremely difficult.
If the product is widely known and process that will avoid specific problems.”
the dryer is part of a processing line
that has not changed in recent years, strategy for drying, and this is inside the drying process or outside
the drying equipment has likely been equally important with a new or of it. Test can also simulate changes
tested numerous times. But for a new existing process where testing on a before they happen, to determine
process and product, the possibility smaller scale would save money on what the impact will be on the
of drastic changes in processing wasted product. process and the product.
variables makes testing mandatory. Product development is probably For food applications, tests that
From small scale pilot dryers to state- the most interesting but most consider food safety are paramount.
of-the-art laboratories, a supplier challenging experience any research Drying, roasting, heating, toasting
expert in thermal processing will team can face, and brings many and tempering, can have a direct
have knowledge of the widest range questions. How will the product impact on food stability. In many
of technologies. react to heating, cooling, tempering, cases, a thermal process acts as kill
Laboratory testing helps identify humid air and agitation? How can step destroying potentially harmful
processing challenges and the the product achieve the desired microorganisms. Running a test
appropriate technology. For instance, characteristics? And, is the test under special conditions, using a
if product sticks to the dryer surface, product representative of what can surrogate organism identical to the
clumps, becomes brittle and breaks, be processed in the production line? real pathogen in its biological
or produces fine dust, testing will The answer to this last question is response, can determine the
enable the drying manufacturer to yes, if the exact same technology is processing conditions--temperature,
design a drying process that will designed for production by a reliable air velocity, retention time and
avoid specific problems. It also helps manufacturer of thermal processing thickness of the product-- necessary
the plant process engineer plan equipment. But what if a company to achieve a safe process.
processing equipment needed before acquires an old facility or used From confirming product
and after the dryer. equipment and needs to adapt the characteristics and determining
Tests can examine small amounts of existing equipment to a new precise parameters to scale up, to
raw or wet product under different product? In this case, the original verifying food safe processing, lab
temperature, air flow and air humidity equipment manufacturer can testing is essential. Experienced
patterns. A test unit should be provide guidance through small applications engineers with global
capable of changing the quantities of scale testing. state-of-the-art laboratories can
initial product, and the experimental provide the expertise needed for
data should be able to be scaled up to THE IMPORTANCE drying success. l
an industrial size process. The test unit OF FOOD SAFETY
should also allow flexibility, to split But there are times when a process
the process into zones or stages, must be modified upstream for the
which will allow process conditions to drying process. For instance, a drastic
change in every zone. change in product formulation, a
change in raw materials, or a change
IDENTIFYING in a fundamental upstream
THE DRYING CURVE process—such as a change in a
This is the most important reactor or a catalyst in the chemical
information to gain from testing industry—can dramatically impact
because it tells how fast a product the process and cost of the final
will dry under very specific product. Testing can determine the
conditions. Conducting experiments best way to counteract the negative
that change processing conditions impacts on the drying process by
will help determine the optimal identifying the variables to change
POTATO PROCESSING • Issue 2/2020 21Process – Sorting
Identifying Foreign Material
with the Latest Technology
In digital sorting, to optimize performance, the system must be designed specifically for
the products being sorted and properly sized for the application. It must also be well
maintained by the user to prevent diminishing performance.
By Dan Orehov
I
n digital sorting, performance is sorting whole potatoes, the Herbert system on the Oculus sorter achieves
typically measured as a ‘defect Oculus sorters were recently added to 20 percent more potato surface
removal rate’ as well as a ‘good-to- the Key sorting product range. inspection to improve sort
bad ratio.’ Sophisticated sorters Inspecting tubers with 360° vision, efficiencies and offers gentler
typically achieve defect removal rates Key’s Herbert Oculus sorters detect handling than traditional cascade
of 90 to 99 percent or higher. The color defects, diseases and surface sorters. Compared to other 360°
good-to-bad ratio often ranges from abnormalities. This includes skin sorters, Oculus is the only sorter that
1:4 to 1:10 and is sometimes as high discoloration, green and dark colors, can reach capacities of up to 80
as 1:50 or 1:100. These results depend bumps and notches, mechanical metric tons per hour,” says Karel Van
on the nature of the product, the damage, common scab, cracks and Velthoven, Advanced Inspection
effectiveness of the sorter’s infeed black dot. Oculus is ideal for sorting Systems Product Marketing manager
and the pitch of the sorter’s ejection pre-peeled whole potatoes, either at Key Technology.”“For potato strips,
system, among other things. unwashed or washed, in or VERYX is our best-selling digital sorter.
immediately following storage to Featuring sustainable all-sided
CHALLENGES FROM A TO Z eliminate defects and FM and identify surface inspection, unique multi-
The primary challenge associated the dimensional profile of incoming sensor Pixel Fusion™ and the highest
with sorting wet potato products raw whole potatoes to improve resolution cameras and laser sensors
comes from the splatter that can downstream processes. For potato on a digital sorter, VERYX removes
obstruct sensor windows, light strip sorting, Key’s VERYX® continues more FM and the right amount of
sources and backgrounds, which to lead the industry with the most product defects to make grade while
hurts the sorter’s performance. For advanced features. As the world’s only virtually eliminating false rejects to
whole potato sorters, the biggest sorter that is able to inspect product maximize yield,” Van Velthoven adds.
sanitation challenge comes from dirt. entirely in-air with both top- and
Here, high-performing mechanical bottom-mounted cameras and laser DETECTING
pre-cleaning solutions and the sensors, VERYX achieves sustainable FOREIGN MATERIAL
sorter’s mechanical design help to all-sided surface inspection to detect One of the most important
overcome the challenge. and remove more FM and defects. characteristics that modern optical
In the case of Key Technology, for “For whole potatoes, the 360° roller sorters must have is flexibility. In fact,
22 Issue 2/2020 • POTATO PROCESSINGProcess – Sorting
sorters must be able to identify any
kind of defects even if they have the “Suitable for both wet and frozen potato
same color of the product. In order to
do so sorters should have many strips, a Sort-to-grade-enabled sorter
frequencies, analyzing the light by
reflection, fluorescence and recognizes and categorizes every surface
translucency, and make shape and
dimension analysis. defect and the dimensional characteristics
Representatives of Raytec say that
machines can offer an efficiency very
of every individual strip and makes each
close to 100% on foreign bodies and
higher than 90% on the other defects.
accept/reject decision based on how it will
On discarded products Raytec impact the aggregate ‘in the bag’ grade, as
guarantees the presence of
maximum 5-7 good potatoes every defined by the processor.”
100 rejections for whole potatoes and
15-20 good units every 100 rejections Karel Van Velthoven, Key Technology
for cut potatoes.
“We are more and more focusing on
the precise detection of length and
shape of frozen french-fries. In this
case the presence of short or curved
fries makes the difference between a
second quality product and a
premium one. Since our peculiarity is
the high definition and the very low
margin of error, this sector is a fertile
ground to invest in,” say Raytec
representatives. “One of the most
important innovations in the potato
sorting sector is the application on
unwashed potatoes. The most
relevant problem consists in
separating potatoes from stones
because they are both covered with
soil and the tubers underneath are
invisible. The optical sorter
RAYNBOW uses its high-speed
double vision system to remove general. CURIOSITY deserves a procedure not only reduces wastes
stones, soil clumps, green and rotten particular mention not only because and contributes to improve the
potatoes and its effectiveness has it is the company’s latest model, but sustainability in food processing, but
been recently proved in our also because it is the only machine it is economically efficient for
installation at AKP Group in North which responds to the new American companies,” Raytec representatives
Lincolnshire, UK,” they add. guidelines dictated by representatives say. “Raytec’s machines can offer an
Raytec has a wide range of optical of the major GDO, fast-food chains efficiency very close to 100% on
sorters for potatoes which are able to and other important players in the foreign bodies and higher than 90%
respond to the different needs of the food processing sector. Moreover, on the other defects. On discarded
potato processing phases. The Raytec can also provide solutions for products Raytec guarantees the
RAYNBOW model is, for example, sorting frozen french-fries and other presence of maximum 5-7 good
applied for washed and unwashed cut potatoes. In fact, the model potatoes every 100 rejections for
potatoes, so it collocates at the DRYCE, thanks to its high-resolution whole potatoes and 15-20 good units
beginning of the processing line. cameras that examine the product every 100 rejections for cut potatoes.”
RAYNBOW can sort peeled potatoes using the "free fall double side view" Coming back to Key Technology, with
but, to detect very small dots, Raytec system, is able to analyze 100% of the the acquisition of Herbert Solutions
designed the optical machine Dryce surface of each product. earlier this year, the company has
with an optical resolution of only “All our sorters can be equipped with added whole potato sorting
0,3x0,3 mm and finger ejectors. a double reject system, in this way we technology to their family of world-
For processed products, for instance, can differentiate wastes from second class equipment and enhanced their
the models SPRAY, DISCOVERY and quality products which can be portfolio of potato processing
CURIOSITY can be used for chips, destined to other process like potato solutions. The Herbert Oculus for
french-fries and cut potatoes in puree, flakes and croquettes. This whole potato sorting enables Key to
POTATO PROCESSING • Issue 2/2020 23Process – Sorting
offer a broader set of integrated
systems throughout the potato value
chain that will advance the custo-
mers’ product quality, production
efficiency and yield. Key’s Herbert
Oculus sorter has a leading position
in the fresh pack potato industry and
is quickly gaining traction in potato
processing plants inspecting pre-
peeled whole potatoes. higher throughput than any other to the cutters, so downstream digital
Moreover, the VERYX sorters are ideal 360° full-surface whole potato sorter sorters can focus on FM that is
for wet and frozen potato strips and on the market. For potato strips and inadvertently introduced during
specialty potato products, and Key’s specialty products, our family of production, either from faulty
Optyx sorters continue to lead the VERYX sorters includes systems of equipment upstream or careless
potato chip/crisp industry. Beyond various widths to satisfy a wide range operators. Unlike other suppliers in
their state-of-the-art sorters, they of capacity requirements. The largest the market, Key offers both optical
have a range of mechanical solutions VERYX is the B210, which features an sorters and mechanical grading
that we can integrate pre- and post- inspection area that is 2100-mm wide solutions, so their customers benefit
sorting to optimize the customers’ and offers a production capacity in from a seamlessly integrated
product quality, yield and excess of 23 metric tons of product customized solution from one source.
process efficiencies. per hour, depending on the
“For whole potatoes, Key’s Herbert application,” explains Van Velthoven. KEEPING SANITATION IN MIND
Oculus sorter is capable of sorting up Most foreign material (FM) from the Keeping a sorter clean helps
to 80 metric tons per hour, depending field, such as rocks and dirt, is maximize FM and defect removal and
on the potato variety, which is a removed by mechanical systems prior minimize false rejects to improve food
safety and increase yield. On VERYX,
Key positions sensors, light sources
and backgrounds away from product
splatter. This innovative design helps
keep these surfaces clean, enabling
us to configure VERYX to achieve full-
surface inspection sustainably
throughout the longest production
cycles in the most demanding, high-
volume environments using entirely
in-air top and bottom viewing.
At the same time, Raytec
representatives say that the company
is always attentive to the latest food
safety standards. For this reason, it has
created a new machine that makes its
strength in the totally hygienic
concept. CURIOSITY, presented at
“Machines can offer an efficiency very
close to 100% on foreign bodies and
higher than 90% on the other defects. On
discarded products, Raytec guarantees
the presence of maximum 5-7 good
potatoes every 100 rejections for whole
potatoes and 15-20 good units every 100
rejections for cut potatoes.”
Raytec
24 Issue 2/2020 • POTATO PROCESSINGProcess – Sorting
Cibus Tec in 2019, is the first belt cameras on a sorter to detect the 5. Add Sort-to-Grade software to
sorter which can replace its conveyor widest variety of FM and defects. achieve the most complex final
belt in only five minutes. In addition, 2. Leverage sensors with higher product quality specifications
the sliding guides of the belt can be resolutions to detect smaller FM without operator intervention
disassembled without the use of tools and defects. while increasing yield and
for a deep and hygienic cleaning out 3. Add Pixel Fusion to find the eliminating mechanical length
of the machine. This technology has most difficult to detect FM and grading equipment.
been adopted precisely to meet the subtle defects while minimizing 6. Add Information Analytics software
hygiene measures promoted in the false rejects. to turn a sorter into a data center
United States and Raytec is sure that 4. Combine top- and bottom- that collects, analyzes and shares
could be adopted as a technological mounted sensors to see all sides of production and product data
standard for all kind of food sectors. each object to detect and remove with the enterprise to optimize
more FM and defects. line management. l
THE WASTE ISSUES
To reduce waste and improve
sustainability, potato processors are
increasingly using sorters equipped
with powerful Sort-to-Grade (STG)
software. Suitable for both wet and
frozen potato strips, a STG-enabled
sorter recognizes and categorizes
every surface defect and the
dimensional characteristics of every
individual strip and makes each
accept/reject decision based on how
it will impact the aggregate ‘in the
bag’ grade, as defined by the
processor. By controlling the output
for defect types and strip lengths that
must be managed to a particular
grade or “spec,” STG accurately
maintains the most complex final
product specifications without
operator intervention while
increasing yields by one to three
percent and enabling processors to
eliminate mechanical length grading.
Moreover, because each processor is
unique, there is no ‘must have’ list that
applies to everybody. Having said
that, Key Technology concludes that
some popular options are as follows:
1. Combine laser scanners and color
POTATO PROCESSING • Issue 2/2020 25You can also read
