Improve potato strip quality and yield

Turkish processor Konya Seker decided to try something different on its potato strip production line. Unlike other potato processors that use optical sorters to remove defects on their primary lines, Konya Seker relies on an ADR5 automatic defect removal system from Key Technology. This application, called the ADRFirst solution, maximises product quality and increases yields at Konya Seker.

The ADR 5 identifies the same kinds of defects on potato strips as many optical sorters but the removal of these defects is handled differently. Sorters remove the entire strip that has a defect while ADR cuts the defect from the strip and removes only the defect. Compared to lines with only a sorter, ADRFirst achieves the same defect removal rate while reducing by-product yield loss by 75 to 80%.

Currently, most potato processors use a sorter on the primary line and an ADR on the sorter’s reject stream to reclaim good product. This traditional configuration typically achieves a 64% defect removal rate. ADRFirst enables a processor to achieve an 80-95% defect removal rate while eliminating the capital cost associated with the sorter.

The ADRFirst solution is equally effective for companies like Konya Seker that must overcome poor raw product quality as it is for companies with typical raw product quality that are looking to satisfy upscale customers by producing the highest product quality. In addition to its high defect removal rate, ADRFirst allows processors to control the length of strips, which reduces bag seal failures, improves line flow at gates and reduces product breakage, all while meeting product specifications.

The ADRFirst at Konya Seker is part of an integrated solution that extends from the cutters to the blancher. The Key-supplied equipment includes a dewatering shaker, sliver sizer remover (SSR), nubbin grader, Iso-Flo infeed shaker, ADR 5, a second nubbin grader, and pump tank. This line produces peeled and peel-on straight cuts and crinkle cuts from 7 to 18 mm in size.

The ADR 5 features high-resolution visible infrared cameras, a special belt conveyor, a rotary cutter and Iso-Flo vibratory conveyors that align, singulate, inspect and trim potato strips at production rates of up to 9.5 tonnes per hour. The ADR 5’s LED light source produces a more stable light over a much longer period than fluorescent lights, which improves inspection accuracy and reduces lighting maintenance. The air-actuated knife system on the ADR 5 cutter-wheel improves cutting accuracy and equipment reliability compared to water-activated knife systems.