Peanut drying process optimised using moisture monitoring system

Producers Peanut was founded 20 years ago by a group of local farmers in the US who were seeking to move their peanut crops to market more efficiently. The business now dries over 25,000 tons of peanuts in just three months during peak season and recently transformed the process using WECO’s PeanutTek active moisture monitoring system, which provides real-time, continuous in-shell moisture readings to help maximise production efficiency, improve worker safety and enhance product quality.

“For decades, the peanut industry has relied on manual sampling to monitor moisture levels during drying, but it’s been far from ideal. We had people using ladders to climb on top of trailers and get gallon-size samples, which was inconsistent and prone to errors. More importantly, we were wearing out our workers and safety was a tremendous concern,” said Ron Dozier, General Manager at Producers Peanut. “The old approach was also inefficient — we had to collect samples several times per load, requiring constant attention and documentation.

“We saw other types of nut processors using sensor plates to monitor moisture during drying and we really understood the potential, so we knew we had to find someone who could turn that vision into reality for us. That’s what first led us to WECO. They have decades of experience with moisture monitoring, and we worked closely with them to adapt their technology specifically for peanuts.”

WECO’s PeanutTek is an advanced active moisture monitoring system that uses a series of sensor plates installed in each semi-trailer or wagon to collect moisture data from a substantial sample size. These sensor plates continuously monitor the moisture content of the peanuts during the drying process, providing real-time data to a centralised computer. The system can be programmed to automatically turn off burners when the moisture of a load reaches a predetermined set point. This control is designed to ensure consistent drying across all loads, minimising the risk of over drying or under drying. Additionally, the system provides up-to-date dryer temperatures, enabling fine-tuning of gas pressure which is designed to ensure all burners are operating at maximum efficiency and speed.

According to Dozier, the WECO system has significantly improved its drying process. “Now, we simply connect the load to the dryer and hook it up to the system. No more climbing on trailers, collecting sample buckets and shelling the peanuts to determine the status. We get live moisture readings that I can monitor from my office, home or smart device, and I can even adjust settings remotely. Once the load reaches the desired moisture level, PeanutTek turns the dryer off instantly.”

Dozier said the system has also been of benefit for employee safety. “Now that workers can monitor moisture levels from ground level, we’ve significantly reduced the risk of accidents”

There have also been some noted enhancements to product quality since implementing the system. By sampling a wider zone consistently and turning dryers off at the right time, the system is designed to achieve an improved moisture reading and dry time compared to traditional, manual methods. This improvement is especially valuable for Producers Peanut’s seed peanut products, which require specific moisture levels to preserve germination potential. “Plus, by optimising the drying process, PeanutTek has helped us cut down on energy consumption, which reduces our operational costs and aligns with the market trend toward sustainability,” Dozier said.

PeanutTek’s software, AgTrack, facilitates its remote monitoring capabilities and data collection. By tracking crucial metrics like drying time and moisture curves, the system can provide insights to help the business refine its processes and make more informed decisions.

Top image credit: iStock.com/White Bear Studio