The most significant challenges when processing fresh produce
In the food manufacturing industry, it is essential for owners and operators to be aware of the requirements associated with their applications and put in appropriate measures to address them.
Different products carry different challenges, and the fresh food sector brings its own unique set of obstacles that food processors must overcome in their operations.
By being aware of the potential issues affecting their products, manufacturers will be able to work out how to maximise results across their lines, leading to increased productivity, enhanced product control and higher customer satisfaction. Understanding these factors will also enable you to identify and install compatible systems in your plant, offering a better return on investment and greater efficiency.
In this blog, we have detailed the most significant challenges fresh food processors must handle in their daily production and how they may address them with the right practices and systems.
Delicate handling
Fresh produce, such as fruit and vegetables, tend to be fragile, making them susceptible to bruising or adhesions. Damaged products will be rejected by supermarkets and are less likely to be bought by the public. So, any production line handling such items must do so delicately to reduce any damage.
During the production process, fresh produce will come into contact with many touchpoints, such as weigher load cells, conveyor belts, inspection systems, packaging stations and other sorting functions. At each of these points, there is potential for the produce to be damaged – particularly by hard, metal machines that are used to speedily process sizeable loads.
It is therefore fundamental for manufacturers to use systems that allow careful handling of their products at every stage of the line. In some cases, this may mean manual handling via static scales. However, automatic systems have become increasingly able to process fragile substances, with low drop heights that minimise the risk of bruising – without compromising on accuracy, efficiency and speed.
By utilising systems with these capabilities, processors will ensure the proper production of their fresh food goods while reducing the possibility of damage before it reaches its final destination.
Hygiene
In any food processing plant, strict hygiene levels should be adhered to at all times. However, with fresh produce, this is especially important.
Fresh produce carries a higher risk of bacteria, such as listeria, salmonella and E. coli. If consumed by humans, this could lead to food poisoning, viruses and even death. Processors must ensure cleanliness across their production line to avoid the presence and spread of such bacteria, in line with strict food standards.
This means adopting adequate hygiene measures in the workplace, such as encouraging staff to regularly wash hands and wear appropriate protective gear. It also means having a systematic and frequent cleaning regime in place, in which machines, equipment and workspaces are thoroughly washed and treated.
Due to their nature, fresh produce tends to be messy. Moisture contained in fruit, vegetable and meat products may leak out during production, leaving residue on surfaces and causing applications to ‘stick’.
This means manufacturers must seek out systems that reduce the impact of messy residues from fresh produce. The best way to do this is to install machines with anti-stick surfaces (such as stainless steel or dimple plated), waterproof designs and ease-of-cleaning features.
You should also check the IP rating of any system you purchase, as this will detail how well protected the machine is against moisture in its enclosures. This will help you determine how easy it is to clean, as well as whether it will be able to withstand residue from your applications without compromising the functionality.
By utilising systems that are designed with hygiene in mind, you will be able to prevent products from getting stuck on your line, while allowing you to quickly clean the production line between batches and avoid cross-contamination. This will help you to reduce the spread of bacteria across the line and maintain high levels of productivity.
Contamination
The majority of fresh produce either comes from animals or is grown outside by arable farmers. Exposure to the outdoors makes these products more susceptible to forms of contamination such as dirt, insects, stone and bone. It is also nigh on impossible to eliminate the risk of human tampering – as seen in the 2018 ‘needles in strawberries’ scare.
As fresh produce continues along the production journey, it may become subject to further contamination, such as glass, metal and plastic, through transportation and handling problems.
If contaminants go undetected and end up being consumed by customers, unpalatable risks can occur such as choking, injury, illness or even death. For businesses, this can lead to costly product recalls, rising customer complaints, negative publicity, fines and legal repercussions.
When processing fresh produce, manufacturers must address these potential contaminants to avoid unfavourable consequences. While good hygiene practices should help you to eliminate microbial and chemical contamination – such as from bacteria and pesticides – additional solutions will be needed to address physical contamination, such as bones and metal.
Inspection systems and subsequent quality control processes are the best way to identify and eliminate contaminants in your products. There are now many solutions available to manufacturers, such as metal detectors, checkweighers and x-rays, all of which will detect a variety of physical contaminants and help you to reduce their presence in your plant. The best equipment will provide real-time data enabling you to analyse areas where produce is coming into contact with contamination and take quick action to solve the issue.
Manufacturers that incorporate rigorous inspection practises in their fresh produce processing lines, reduce the risk of contamination while enjoying the benefits of compliance, less waste and better quality.
Speedy production
Compared to other industry applications, fresh produce has a short shelf-life. This means that manufacturers need to process such products quickly to get them in front of customers as soon as possible.
Production lines need to be optimised to deliver results at high speed, but without compromising on quality and while handling products delicately. Finding the fine balance between these different needs can be a challenge.
Increasing innovation in automatic systems now means that many can offer careful and hygienic handling while processing goods at high speeds. Features to look out for are number of weighments per minute (the higher, the better), ability to pre-set programmes (saving set-up time) and infeeds that support the flow of product. Systems with high load capacity may also be beneficial, enabling you to process large batches at any one time.
Similarly, machines boasting high accuracy – by providing real-time feedback and reduced rejects – will allow your processes to work smoothly and correctly. This minimises the chance of error and intervention, meaning you achieve high levels of productivity without the worry of waste and rejects. As a result, you can reach the intended levels of output more quickly and allow your goods to progress to the next stage.
Portion control
The final part of most processing lines is packing products into the designated weight limits as set out via project guidelines and labelling. Whether your product is being sorted into crates or wrapping, it is essential to ensure your product meets requirements and does not fall over or under the set limit.
With fresh produce, when you are dealing with potentially high volumes of product at any one time, it is essential to be able to effectively control portions and ensure the right amount ends up in your packages.
In the event that you are combining ingredients, such as for mixed fruit or vegetable packs, you will further need to choose systems that precisely count and mix ingredients, so they remain within the specified levels.
Semi-automatic and automatic weighers should be chosen that offer accurate weighing and data analysis regarding the quantities flowing through your line. Flexibility is also critical. Pack sizes and formats may need to be changed during production due to a sudden change in demand, so systems that allow for easy adjustment of pre-set programmes are a must.
By finding suitable systems that provide accurate portion control, you will be able to follow the set limits for products, as well as reduce waste and keep costs down. You will also have happy customers and satisfied consumers – and that increases your chance of securing repeat business and new contracts.
Finding the right solutions for you
Understanding the challenges you’ll likely face when processing fresh food will enable you to successfully plan projects in advance and determine which systems your plant needs.
With the right processes and systems in place, you will overcome the barriers associated with fresh produce processing and maximise results – including increased quality, accurate portions, enhanced consumer safety and high-speed production.
At Yamato, we offer a range of solutions for fresh produce applications, covering weighing, sorting and inspection. By providing increased accuracy, speed and hygiene, as well as many other desirable features, our systems are suitable for a variety of fresh food products.
Find out more about our products and specifications or get in touch today to discuss the possibilities.