Advanced machinery and systems have revolutionized various stages of potato handling, from cutting to sorting, significantly improving product quality, consistency, and production rates.
High precision cutting equipment ensures uniform potato pieces, whether for French fries, chips, or other products, leading to better cooking results and customer satisfaction.
Optical sorting technologies, utilizing cameras and lasers, can rapidly inspect potatoes for defects, foreign materials, and size variations, maintaining high quality standards and food safety. Automated conveying systems and robotic handling reduce manual labor, minimizing product damage and contamination risks. Additionally, data-driven process control systems optimize resource usage, reduce waste, and ensure consistent output quality.
These – and other – technological advancements not only boost productivity and profitability for processors but also contribute to more sustainable operations by maximizing yield and minimizing energy consumption. As consumer demands for quality and variety continue to evolve, the integration of cutting-edge technology in potato processing remains essential for staying competitive in the global market.
According to Alan Major, chief sales officer at Urschel, the company has maximized slice engagement with the patented MicroAdjustable series heads which greatly reduces miscuts and increases in-spec, targeted cuts. This translates to increased usable products and consistent fry times, less oil, and cost-savings. Urschel has showcased its new MicroAdjustable series of potato slicing heads for the Model CC, and Alan Major explains its benefits.
“The MicroAdjustable SL-14 series patented by Urschel for the Model CC maximizes cutting action with 14 cutting stations versus the fully adjustable, standard 8-station head, so customers benefit from potentially doubling the capacity. Options on the CC include a 22″ (559 mm) or 32″ (813 mm) cutting chamber. Customers with the 813 mm cutting chamber, paired with an SL-14 head, and powered with a 5 HP (3.7 kW) or 10 HP (7.5 kW) recognize tremendous benefits.”
The MicroAdustable SL-14 flat slice heads manufactured by Urschel allow slicing knives to be replaced quickly without tools and without removing the head from the machine when equipped with quick release clamps. The Urschel patented SlideLocc system incorporated in the .212″ V MicroAdjustable SL-14 head uses a simple angled wrench and optional tools. The head is removed from the machine using the 2 lift handles conveniently built into the design. The angled wrench is used to loosen fasteners. The optional torque wrench may be used to loosen or tighten the fasteners. The customer slides in the blade, locks in place, and then tightens, Major explains.
Potato processors also explore further size reduction capabilities via the Comitrol Processor line of particle size reduction machinery manufactured by Urschel. The line mills food products into free-flowing, viscous slurries to provide value-added opportunities. The Comitrol milling series by Urschel operates by incrementally shearing the product in a rapid, controlled manner called comminution. The Comitrol particle size cutting solution has assisted thousands of food processors to extend and build their capabilities and SKUs. „Urschel customers are looking for higher and higher capacities. The big processors are looking for standout potato products to continue to stay ahead of their competition. New cuts and decreased waste,” Major says.
“Urschel partners with leading potato processors to develop new shape cuts and cutting methods. Urschel personnel assist potato processors around the globe to make sure we are fully supporting the needs of the industry. Urschel engineering and product development engage with food processors to create new patented cutting methods and improve on existing ones to meet present and future goals.”
Regarding the equipment’s operating and maintaining side of things, Urschel’s global network of sales and service spans the globe. “As the global leader in food cutting technology, Urschel customers have relied on us to deliver the right cutting machinery for the needs of their production line,” Alan Major points out.
“Founded in 1910, Urschel food cutting machinery, is proud to have grown alongside the food processing industry. An Urschel customer may begin with a test-cut on different types of Urschel machinery to determine the best fit. Complete information about each model may be discussed in depth. Urschel communicates with customers to answer questions specific to their requirements including any operational or maintenance topics. After the sale, service and support continues. Service is available over-the-phone or in the customer’s plant for any necessary training. Urschel is available for scheduled maintenance and service as needed by the customer. In-depth operating manuals depict concise, clear procedures. Urschel also maintains a multi-million-dollar inventory of commonly replaced parts available for shipment on customer demand. Each part is engineered to fit and function like the original.”
Additionally, Urschel offices surround the globe to assist and partner with leading potato processors. Urschel respects these relationships and honors all exclusivity agreements. Leading processors benefit from Urschel’s in-depth cutting and manufacturing knowledge backed by the assistance, support, and security they need in a long-term capital equipment provider. While the Urschel Model CC Slicer is well-known throughout the world as the leading crisp/chip slicer, the DiversaCut line has been gaining momentum in niche potato products. There are more and more potato products bridging the gap between crisps/chips and fries. Niche markets in waffle cut fries, lattice crisp/chip slices, and small cut frites are continuing to expand.
More Innovations to Come
“Urschel takes part in every major food processing industry show around the globe. Urschel has been showcasing the MicroAdjustable series, the many knives we manufacture, and the latest machinery to view first-hand. We are proud to be a leader in the food processing industry and have recently revamped the look of our booths with a complete redesign,” according to Alan Major.
“Emphasized in the new booth design are the many types of food products processed with Urschel cutting machinery support. Urschel will continue to represent the best in cutting technology at shows around the world. It’s important to meet new and existing Urschel customers and help them strategize successful cutting solutions to improve their production lines. Urschel standard slicers and dicers have more optional features than ever before, such as built-in discharge conveyors, longer infeed belts, door swing options, motor size, and more. The new Model CC Slicer frame design is an example of the strides Urschel is continuing to implement. While Urschel accommodates custom requests through a certified print process, customers often decide optional features on a standard machine will fit their objective. Custom type requests are put through a certified print process. With the certified print process, Urschel works with the customer to fulfil specific build requirements, and the resulting machine cost will generally be higher than when purchasing a standard machine,” he adds.
Future innovations and developments from Urschel include even more shape cuts, Major points out. “We are in the process of developing new patented cutting methods that have the potential to be unveiled in the next two years pending extensive research and development. Urschel will also continue to expand on developments on existing machinery in the field to help Urschel customers expand their opportunities.”
Meeting the Industry’s Needs
How is a major player like FAM STUMABO adapting its equipment development to align with emerging trends in potato processing? “At FAM STUMABO, we collaborate closely with our customers to develop or co-develop new product ideas,” company representatives say.
„Our innovations are inspired by global trends, including the rising demand for potato products and the push towards greater automation in production processes. As consumer demand for healthy and convenient potato snacks continues to grow, the market is increasingly exploring new flavors, textures, shapes… In the frozen potato segment, there’s a noticeable diversification in both demand and product offerings. The convenience and versatility of options like frozen fries, wedges, scoop-style fries, and crinkle-cut steak fries, … are driving global demand. Our Food R&D Department and project engineering teams helped to create these new products. Furthermore, our application specialists consistently deepen their expertise in the parameters influencing the cutting of various potato varieties.”
For processors, representatives add, the adoption of advanced potato cutting methods is crucial. These technologies help reduce waste, optimize water usage, and enhance operator comfort, making the production process more efficient and minimizing the risk of human error.
“Through partnerships with leading potato processors and line builders worldwide, we ensure that our innovations meet evolving industry needs. This collaboration results in higher capacity, improved yield, cost savings, and reduced processing time, ultimately adding value for our customers. Our mechanical cutting solutions are known for their reliability, high capacity and cut quality. Their overall goal is fryer stability. We understand the impact of cut accuracy on the frying step, preventing acrylamide formation, reducing scrap, preventing excess moisture and optimizing oil uptake. We don’t just design a standard model, we have the P series in which the capital P stands for «specially designed for Potato cutting», assuring regular cuts, maximum length, and minimum breakage and feathering.” They go on to explain that STUMABO hydrocutting heads and blades are the preferred choice for potato processors around the world, who value their superior cut quality, prolonged blade life, increased efficiency and higher yield.
“We select the best stainless-steel knives for the specific requirements of potato processing to optimize the performance of each machine. This includes the proven Conibot technology, specially developed to maintain superior cut quality when sprouting occurs on potatoes.” FAM STUMABO has introduced a “Total Care Program,” available in several countries, to provide comprehensive support near our customers’ operations. Proximity to its clients is crucial for delivering prompt service, minimizing downtime, and ensuring business continuity, especially during peak production periods. Additionally, the company maintains a stock of spare parts and precision blades locally to ensure timely assistance and efficient service.
“The Total Care Program (TCP) offers our customers a comprehensive range of services designed to ensure the optimal and most cost-effective operation of their machines throughout their lifetime. It encompasses all services that may be needed before, during, and after the purchase of each food cutting machine, providing complete support and maintenance solutions. FAM STUMABO personnel collaborate closely with customers at every stage of the process to ensure the success of their projects. Our team offers free online live chat support, integration assistance, and training courses. We also provide feasibility tests and real-life demonstrations to optimize project outcomes. Furthermore, our experts can recommend additional features to help optimize the configuration of customer applications.”
As representatives explain, TCP stands for a complete service range, encompassing sales (advice from start to finish, expert consultation throughout the selection process); feasibility (to validate and optimize the project, our dedicated team can run a demonstration within one of our test labs or on-site); commissioning (every FAM machine gets delivered with detailed instructions covering operation, cutting tools, cleaning and how to fine-tune the investment); training (mastering the finer details of machine performance and setup is the best way for users to maximize the efficiency and effectiveness of our solutions); support (help desks are provided throughout the FAM STUMABO network); maintenance (boost the lifespan of the investment.
Maintenance is a way to protect it, control upkeep costs, and ensure steady production. Our engineers provide customers with fast and effective maintenance services); repairs (in case of sudden break down our team is immediately at disposal); spare parts & service (all spares and parts offer the customer reliability and come with a full warranty. Every FAM machine has its own recommended spare parts, knives and other auxiliary tools list); refurbishment (after years of operation, we can fully refurbish your equipment so you can extend your manufacturer warranty); and expert advice: our support teams are dedicated to helping, informing, and reassuring the customer every step of the way in his project).
A Platform for Showcasing New Machinery
“Trade shows and industry events are vital for marketing our products, particularly in emerging markets where customers may not yet be familiar with our industrial food cutting solutions,” FAM STUMABO representatives point out.
Participating in these events is a key component of the company’s marketing and communications strategy. When well-prepared and executed, they offer a strong return on investment by generating leads and new business opportunities. Additionally, these events provide an excellent platform for launching new machines.
“Over the past six months, we participated in major tradeshows in the food industry, which provided an ideal opportunity to launch four new machines. During Fruit Logistica, we launched Yuran Capcitec. This robust, high-capacity belt cutter is ideal for dicing and strip-cutting a wide variety of products such as bell peppers, capia, jalapeño and chili peppers as well as raw or blanched greens such as spinach, radish, kale, cabbage… The machine has a large product opening for cutting vegetable products and can be equipped with a feed roll or driven top belt for peppers and leafy-type green vegetables. At Anuga FoodTec, we presented two more new machines. SureTec 240 is a very reliable and durable high-capacity dicer that guarantees peak production in heavy-duty production circumstances, ideally suited for frozen vegetable and large fresh vegetable processors. It features the unique concept of the SureCut unit (SCU). The SCU allows the cutting components to be pre-assembled in one piece and perfectly adjusted, away from the machine. That way even non-technically trained operators can install the cutting tools on the machine in a very fast, uncomplicated and error-free manner. Yuran Hytec 300 is a belt-fed dicer designed to dice, strip-cut and shred a large variety of meat, poultry and alternative protein products. Lastly, Scalibur was presented during Snackex and SNX. This innovative slicer provides next level cutting solutions for slicing potatoes and features the dual rotation technology, a system where the cutting head rotates in addition to the impeller.”
In the end, as representatives explain, tradeshows and industry events are crucial channels for connecting with prospects, customers, agents, and industry peers. They offer an ideal platform for networking, attending or giving presentations, and engaging with a wide audience.
De Marchi Automates Production Line with TOMRA 5B, Increases Productivity by 30%
In a constantly developing market, De Marchi maintains its prominent position by investing in innovative technologies. With the help of TOMRA, the company decided to further automate its production line to increase its product quality and yield.
Since installing a TOMRA 5B sorting machine in February 2023, there have been clear improvements in product sorting and volumes – results which indicate this partnership has only just begun. The De Marchi Group’s operations range from the large-scale cultivation of fruit, vegetables and greens to the production of many different frozen foods and “in Nature” foods for Brazil and abroad.
In a demanding market, the company seeks to go one step beyond customers’ expectations by offering higher-quality, healthier, and, above all, more sustainable products. Agribusiness accounts for over 23% of Brazil’s gross domestic product. Brazil’s fruit and vegetable market has been growing steadily and is now a very important part of the economy.
Although fruit and vegetables are not yet ingrained in the Brazilian population’s diet, their popularity is increasing, boosted by natural and organic foods that consumers favor for their health benefits. Carlos Alberto De Marchi, industrial director at De Marchi, emphasizes the importance of his business partnership with TOMRA. “It gives us several advantages,” he says, “the main one being the increased quality of our product.”
He explains that before the TOMRA 5B’s installation, the process was “completely manual”, but now the TOMRA machine has brought great progress, “not only in terms of resource management but also in terms of economics. Not only was the increase in profitability measurable, but also important was the food safety that the machine added to the product. In addition, we know that labor work is becoming more complex every day. People can’t do repetitive work with a high degree of concentration for very long, so the machine greatly increases reliability in the selection process.”
Six months after installing the TOMRA machine and working with various types of fruit and vegetables, the feedback couldn’t be more positive. Carlos Alberto De Marchi says that “with the automation of the line, we have a 30% increase in productivity and much greater safety in the products we produce, which would have been impossible with the manual process. Moreover, we’re bringing together profitability, reliability, and agility in our processes to reach higher levels. We have exceptional personalized support from TOMRA through various channels, which makes all the difference.”
This partnership is key in a sector as important as fruit and vegetables. “De Marchi is an innovative company with a strong presence on the national and international market, and it’s undoubtedly a very important partnership for TOMRA in the minimally processed fruit and vegetable segment. It’s an honor to supply a high-tech optical food sorting solution to one of Brazil’s largest companies in the sector,” said João Medeiros, area sales manager of TOMRA Food Brazil.
“TOMRA designed the solution together with De Marchi, taking great care over the details because the customer’s range of products is large and requires a complete solution that can add value to all the products in the range. The demonstration of the machine at TOMRA’s modern test center in Santiago, Chile, was also of great importance in defining the project.” The main benefits of using the TOMRA 5B optical sorter are maximum food safety, higher quality product sorting, optimized production line throughput, and ease of operation. Product quality becomes more consistent, and employees who previously worked on sorting can be redirected to other important parts of the production line.
Key Technology Showcases New Sorter for IQF Products
Key Technology, a component of Duravant’s Food Sorting and Handling Solutions group, has launched COMPASS, an advanced optical sorter designed for individually quick frozen (IQF) products.
This innovative system caters to a wide range of food items, including fruits, vegetables, seafood, poultry, and meat. COMPASS’s primary function is to identify and eliminate foreign material (FM) and product defects, thereby safeguarding food safety and ensuring final product quality. COMPASS distinguishes itself in the market through its simplified operation, cleaning, and maintenance processes, making it the most user-friendly optical sorter available. Additionally, it offers a rapid return on investment for processors.
Jack Lee, Duravant Group president of Food Sorting and Handling Solutions, emphasized the unique challenges of IQF production lines: “Processors often handle dozens of different products and change over several times a day. Optical sorters for these applications require a great degree of flexibility and must maintain high accuracy despite significant product changes.”
Lee further highlighted COMPASS’s strengths, noting, “COMPASS’s intuitive user interface and straightforward recipe-driven programming means even entry-level workers with no technical background can easily operate this system to achieve peak performance.”
The versatility of COMPASS extends to various product forms, including whole products, slices, dices, crumbles, and product mixes. Utilizing in-air inspection technology, this chute-fed sorter provides comprehensive product examination without blind spots. Its detection capabilities encompass a wide range of foreign materials such as plastic, glass, metal, stones, and extraneous vegetative matter (EVM) like leaves and toxic weeds.
COMPASS also removes processor-specified product defects with minimal false rejects. For mixed products, the system can be programmed to ensure correct ingredient proportioning. Positioned at the end of the processing line, just before packaging, COMPASS serves as a final quality assurance checkpoint. Its user-friendly design features an ergonomic interface resembling smart devices, allowing for effortless navigation.
The system’s open, washdown-compatible design facilitates easy access for cleaning and maintenance, having been engineered to maximize sanitation while minimizing upkeep requirements. COMPASS’s recipe-driven programming ensures consistent sorting performance across all product runs, proving particularly valuable in high-changeover applications.
Operators can create new recipes or modify existing ones to accommodate product changes without requiring assistance from application engineers or Key service technicians. The system’s modular design allows for multiple size options, catering to diverse customer applications and capacity requirements. COMPASS incorporates advanced features such as object-based recognition for sophisticated shape sorting algorithms and intelligent ejection to maximize sorting accuracy while minimizing false rejects.
Every COMPASS unit comes equipped with Key Discovery, a powerful suite of data analytics and reporting software. This tool enables the sorter to collect, analyze, and share data about every object passing through the system. Key Discovery’s capabilities extend to revealing patterns and trends, providing processors with valuable insights into their operations and potential areas for optimization.