The frozen food sector places a lot of value on optical sorting technology because it provides several advantages that improve efficiency and quality control. Optical sorting allows for accurate and automated examination of frozen food products thanks to its sophisticated sensor-based systems, guaranteeing that only high-quality products reach the market.
With the help of this technology, many flaws, including foreign objects, color, blemishes, and even size irregularities, may be found and eliminated, guaranteeing that buyers obtain goods that adhere to high standards of quality. Optical sorting quickly and precisely separates frozen food products, which not only raises the quality of the finished product overall but also reduces the possibility of contamination and increases food safety. Additionally, by speeding the sorting procedure, minimizing human labor, and maximizing production throughput, this technology boosts operational efficiency. As a result, frozen food producers and distributors see cost savings and increased productivity.
A Successful Partnership
After extensive testing, research, and validation, global food manufacturer Nestlé decided the TOMRA sorter met their needs best and cited the Smart Sort technology as the deciding factor. The quality check process involves taking the raw material out of totes or cases, putting it through a series of inspections, and then putting it back in totes after it has been determined it is safe and desirable. The first two examinations see the toppings pass through a bulk X-ray machine and then over a magnet to remove any remaining metals. The final check sees the remaining good materials travel through the TOMRA optical sorter before finally returning to the totes.
Food trends continually change and stress the importance of an operation’s capacity to adapt quickly. Being agile and evolving to meet the customers’ desires for higher-quality products makes a world of difference. Employing TOMRA sorters has positively impacted Nestlé’s procedure, adding an invaluable point in the process to reduce the risk of foreign matter ending up in the final product. With their TOMRA Nimbus, Nestlé processes around 15 million pounds of raw material at the Solon, Ohio facility in a year, where they distribute toppings to three other production locations around the United States.
The machine’s robust capabilities allow production lines to continue running the highest volumes while also rendering data that allows them to notify suppliers of product quality trends earlier in the supply chain. Nestlé utilizes TOMRA optical sorters for their frozen food operations at Solon (United States) and at their Nonnweiler facility in Germany. A corporate recommendation and Nestlé’s commitment to food quality & safety led to the discovery and implementation of TOMRA sorters. Their dedication to continuous process improvement, food safety, and offering their customers the highest quality product keeps bringing them back for more.
Selecting the Right Sorter
When selecting a sorting machine for a frozen food processing plant, the first consideration is what unwanted materials or product defects you need the machine to detect and eject. Some of these might be difficult to detect, and sorting machines differ greatly in their ‘seeing’ ability, according to Jacob Hobbel, TOMRA Food’s global category director for vegetables and fruit. Another consideration is the sorter’s ability to minimize food waste and maximize yields, he explains. “Will the machine work with a low level of false rejects, removing unwanted materials without also removing too much that’s saleable? Machine performance also differs in this respect. Yet another consideration is downtime. The sorter needs to be easy to operate, easy to set-up when switching from one type of food to another, easy to clean, and reliable. It must work well in the tough conditions found in IQF environments, in temperatures can be as cold as -30°C and as hot as 50°C. If a problem should occur, the machine user needs to know the manufacturer will quickly provide technical back-up, whether that’s remotely or by getting a technician on site.”
One more factor to consider is futureproofing, Hobbel explains. “Selecting a sorting machine is not only about current needs, but also what it will take to stay competitive in the future. As we move into an era of digital transformation, sorting machines with Artificial Intelligence will deliver advantages, as will machines which produce usable data.” For example, connectivity to the TOMRA Insight customer portal and cloud-based data platform can show operators live data which enables them to make line efficiencies almost instantly. This data can also ensure that when frozen vegetable products are mixed, each bag is packed with exactly the right mix. And by accessing data retrospectively it’s possible to quantify the standards of raw materials from suppliers and to make better-informed business decisions.
To read the entire article, please access your complimentary e-copy of Frozen Food Europe May-June, 2022 issue here.