Drum sorter helps customers increase production capacity by 30%

In August 2023, our company successfully delivered a customized fruit and vegetable cleaning, drying, and sorting line to a US customer. With efficient and accurate sorting performance, we helped the customer increase production capacity by 30% and significantly reduce labor costs.

Ⅰ. Customer Needs and Challenges

Our clients specialize in deep processing of fruits such as apples and citrus. With the increase in order volume, its original production line is facing three major pain points:
 
1. Equipment aging and frequent malfunctions: The existing equipment is severely aging and experiencing frequent malfunctions, resulting in prolonged downtime and seriously affecting production efficiency.
2. Risk of residual water after cleaning and air drying: The residual water rate on the surface of the original equipment after cleaning is high, which can easily lead to the growth of microorganisms in subsequent processing.
3. Lack of classification levels: The original equipment had too few classification levels, which could not meet the needs of product market segmentation.
 

II. Solution: Full-process Intelligent Sorting Line

In response to the above issues, our company provides an integrated solution of drum type sorting machine and intelligent detection system:

1. Drum type sorting machine: the core of efficient grading

Structural design: Using 304 stainless steel rollers, the surface is smooth without dead corners and meets FDA food contact standards. The drum has a length of 8 meters and a diameter of 1.2 meters. It is driven by a variable frequency motor and the speed can be adjusted to 5-15 revolutions per minute.
Sorting principle:
Physical grading: Size grading is achieved through sieves with different apertures (50-100mm), with an accuracy of ± 1mm, and can process 20 tons of fruit per hour.
Dynamic magnetic system technology: Equipped with permanent magnets, metal impurities are removed through magnetic field adsorption, while preventing material adhesion and ensuring sorting purity.
Energy consumption optimization: Using energy-saving motors, energy consumption is reduced by 25% compared to traditional equipment, saving over $15000 in annual electricity bills.

2. Cleaning and Drying System: Ensuring Full Process Cleanliness

· Three-level Cleaning:
i. Bubble Cleaning: High-pressure bubble water flow is used to remove surface sediment, combined with ozone sterilization, with the degradation rate of pesticide residues exceeding 90%.
ii. Brush Cleaning: Soft brushes gently clean the gaps in the fruit skin, avoiding damage to the fruits.
iii. Spray Irrigation: The circulating water system reduces water consumption, with water consumption being 40% lower than that of traditional equipment.
· Drying Process: Centrifugal fan + hot air circulation is used, reducing surface moisture to ≤ 5% within 30 seconds, avoiding oxidation and color change during subsequent processing.

3. Intelligent Detection and Data Management

· Multi-dimensional Detection:
· Visual Recognition: 4 sets of industrial cameras perform 360° scanning to identify fruit diameter, color, and surface defects (such as insect bites, fruit rust), with an accuracy of up to 1mm².
· Near-Infrared Spectroscopy: Non-destructive testing of sugar content, acidity, and internal lesions (such as apple rot disease), with a detection accuracy rate of ≥ 95%.
Data Traceability: Integrated with IoT modules, real-time recording of sorting data for each batch of products, generating PDF reports for customer archiving, meeting traceability requirements.
 

III. Implementation Results

· Efficiency Enhancement: The daily processing capacity has increased from 15 tons to 20 tons, resulting in direct economic benefits exceeding 500,000 US dollars.
· Quality Improvement: Through precise sorting, the proportion of superior fruits has risen from 65% to 85%, generating additional revenue from premium sales.

 Why Choose Union Machinery?

· Expert Team: End-to-end engineering support from design to commissioning.
· Global Expertise: 11+ years in food machinery, serving 50+ countries.
· Certifications: ISO9001 and CE compliant.
· Custom Solutions: Full-service support, including plant layout optimization.
· Support: 24/7 technical assistance, spare parts availability, 1-year warranty.

Contact Union Machinery Team Today!
If you face production bottlenecks, high energy costs, or equipment compatibility challenges, reach out to Union Machinery!
Free production line diagnosis + customized solution design to help you seize market opportunities!