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Konya Seker maximises potato strip quality, yield

14 December 2010

Unlike other potato processors that use optical sorters to remove defects on their primary lines, Konya Seker relies on an ADR 5 Automatic Defect Removal System from Key Technology

Konya Seker, the innovative Turkish processor, decided to try something different on their potato strip production line. Unlike other potato processors that use optical sorters to remove defects on their primary lines, Konya Seker relies on an ADR 5 Automatic Defect Removal System from Key Technology.

This new application, called the ADRFirst solution, maximizes product quality and increases yields at Konya Seker.

“Thanks to our state-of-the-art equipment and our know-how, we’re able to produce high quality product. Because the quality of our product is so high, McDonald’s is working work with us. Having equipment from Key Technology helped us win that important account,” noted Ilker Cabukol, the factory manager at Konya Seker responsible for the company’s potato operations. “Our production line is the highest capacity potato processing line in Turkey and the most modern.”

The ADR 5 identifies the same kinds of defects on potato strips as many optical sorters but the removal of these defects are 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 75-80%.

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 percent 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 raw product quality in Turkey is limited. When I compare the crop here to what I see in the U.S. or Holland, we have a long way to go. We needed to solve this defect problem so that we could deliver world-class product to our customers. With ADR, we’re hitting our specifications while we’re also maximizing yield,” said Cabukol.

Key’s ADR First 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 from Key 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.

“From the beginning, I wanted to have equipment from Key Technology on the
line at Konya Seker because I’ve had so many great experiences with Key in
the past. I know their equipment is accurate, reliable, and low
maintenance, and their support makes them a great partner. We needed a
partner that we could talk with and solve problems with together. I wanted
Key on board as we put this new line together,” noted Cabukol.

The ADR 5 features high-resolution Vis/IR (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 metric tons (20,900 lbs) 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

“When we compared what we could achieve with the ADR®First solution to all
the other alternatives, it was clear to us that the ADR®First solution was
right for us,” concluded Cabukol. “We’ve gotten everything we expected from
this system and having Key as a partner has been invaluable.”

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