Optical sorting machine enhances efficiency of canning business

McCall Farms is a vegetable-growing and canning business in South Carolina (USA). It was established in 1954 as a tobacco growing company and later switched to canning vegetables and fruits. Today, McCall Farms is one of the leading providers of farm-fresh canned products, offering a wide variety of Southern-style fruits and veg under four major brand names.

However, the company faced challenges related to manual labor in the sorting process. Recruiting and retaining a workforce for sorting tasks proved difficult, leading to issues with product quality and the need for increased manual labor. To improve efficiency and maintain high product standards, McCall Farms shifted to an automated sorting.

After having experimented with different sorting machinery manufacturers, McCall Farms discovered TOMRA.

First, McCall Farms acquired two TOMRA Sentinel II optical sorting machines, which had proven effective. Then, the company acquired the TOMRA 5B, a state-of-the-art belt sorter specifically designed for green beans and other products. It utilizes advanced sensor technology and shape algorithms to achieve high-quality sorting results. The machine's 360° inspection and smart surround view technology ensure swift removal of foreign material, improving sorting efficiency. Additionally, its gentle handling capabilities preserve product integrity.

Upon implementing the TOMRA 5B, McCall Farms witnessed significant improvements. The machine exceeded expectations, achieving a 99% removal rate for all defects at the recommended capacity. Consistency in sorting improved, leading to substantial enhancements in product quality. McCall Farms could maintain their preferred production speed while consistently delivering high-grade products. As a result, the company experienced a remarkable 16-fold increase in production volumes within just four years.

Moreover, the adoption of TOMRA's sorters reduced McCall Farms' dependency on manual sorting, which was inconsistent and time-consuming. This shift also resulted in a reduction in manpower and the production footprint. The TOMRA sorters proved easy to maintain, with accessible windows for cleaning and a user-friendly cleaning mode.

Impressed by the performance of TOMRA's sorting machines, McCall Farms expanded their usage beyond green beans. They incorporated TOMRA Nimbus BSI+ sorters, equipped with Biometric Signature Identification technology, for sorting in-shell peanuts. The success of the TOMRA 5B has prompted McCall Farms to plan the purchase of another unit.

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