The food processing industry is constantly evolving, driven by technological advancements and the need to meet increasing consumer demand. For Rol-Nas Sp. z o.o., a prominent potato processing company in Poland, this meant upgrading their aging manufacturing equipment to stay competitive. Faced with outdated peeling lines that were inefficient, unreliable, and costly, Rol-Nas took a bold step to modernize its production line with the latest food processing technology, focusing on precision, efficiency, and sustainability.
The Challenges of Outdated Equipment
Rol-Nas faced several challenges with their previous peeling line. The old machinery struggled to meet the growing demand for their products, limiting capacity and causing frequent downtime. Additionally, the technology failed to meet modern standards for product quality and consistency, which are essential for staying competitive in the fast-paced food industry. The inefficient systems also led to higher operational costs and increased waste, both of which are significant concerns in a sector where margins can be tight.
Recognizing these challenges, Rol-Nas made the strategic decision to install a new production line designed to enhance the key stages of their process—peeling, scraping, and inspection. After an extensive search and visits to several Western European machine builders, Rol-Nas chose Marcelissen, a company known for its expertise and innovative solutions in food processing equipment.
The New Production Line: Key Technologies and Features
The newly installed equipment from Marcelissen significantly improves Rol-Nas’ efficiency and sustainability. The key components of the new production line include:
- Drum Roller Peeler SKR28/3000: This machine effectively removes potato skins while maintaining their round shape, improving the overall appearance and shelf life of the potatoes.
- Wet Hopper with Outfeed Gooseneck Conveyor BNTZ350/400: This system ensures smooth, accurate dosing between processing steps, facilitating continuous throughput and maintaining production flow.
- Drum Knife Peeler SMT1000/3000: Known for its precision, this knife peeler produces aesthetically pleasing results, preserving the shape of the potatoes while enhancing their shelf life. It operates with a dosed feeding system to ensure consistent results.
- Roller Inspection Belt IR800/4000: The rotating profiled rollers ensure thorough inspection of the potatoes, allowing staff to remove any irregularities before further processing. This increases product quality and minimizes waste.
The integration of these machines into the existing production line was seamless, with a combination of standard and custom solutions to optimize performance. One of the standout features of the installation was the focus on waste management. The waste system ensures that skins and by-products are efficiently gathered and removed, keeping the production hall clean and minimizing the risk of contamination.
Enhancing Efficiency with Remote Monitoring and Automation
In addition to the new machinery, Rol-Nas also implemented a Human Machine Interface (HMI) system for remote monitoring. This system allows operators to track critical process data, including thermal safeguards on motors to prevent overheating, which is essential for predictive maintenance. With various automated programs tailored to different potato types and peeling methods, the system enables operators to fine-tune settings, ensuring optimal performance.
The technical director, Sjoerd Treuen, personally oversaw the operational release and final inspection, ensuring that the line was running smoothly and that the settings were aligned. This hands-on approach not only ensured the success of the installation but also strengthened the relationship between Rol-Nas and their equipment suppliers.
The Results: Increased Capacity and Higher Product Quality
Following the installation of the new machinery, Rol-Nas has experienced a significant increase in production capacity. The old peeling line was no longer capable of handling the volume required to meet market demand. However, with the new Drum Roller Peeler and Drum Knife Peeler, the company can process larger quantities of potatoes in less time while maintaining high-quality products. This improvement is crucial for staying competitive, as it allows Rol-Nas to scale up production without compromising product quality.
Furthermore, the new system has created a smoother and more efficient production process. With seamless transitions between processing steps, the likelihood of downtime has been greatly reduced, and throughput has increased. The integration of the Wet Hopper and Outfeed Gooseneck Conveyor Belt and the Roller Inspection Belt has resulted in a more streamlined process, reducing operational bottlenecks and improving overall efficiency.
The decision to upgrade its food processing equipment has proven to be a pivotal move for Rol-Nas. By embracing the latest technology, the company has significantly improved its production capacity, product quality, and sustainability. The combination of advanced peeling, scraping, and inspection systems, along with automation and remote monitoring, has not only made the company more competitive but also set a new standard for efficiency and cleanliness in potato processing. As the food industry continues to evolve, Rol-Nas’ commitment to innovation and sustainability positions them well for future growth and success.
