Established in 1944, Almondco Australia engages in the supply of almonds for almond-based product processors. In late 2020, they announced Project Optimise, unveiling a 10,000 m² facility next to its processing unit in Renmark, South Australia. This development expanded storage for annual almond yields from grower members, consolidating numerous processing functions in one location.
Planning for this expansion highlighted the requirement for a transportation and storage mechanism capable of handling large volumes of sensitive, raw, and blanched almonds. Almondco partnered with Flexicon Australia, a bulk material handling equipment designer and manufacturer, ensuring local support in line with previous project successes.
Rob Wallis, Application Engineering Manager at Flexicon Australia, noted the company's request for a quote on a new bulk bag filling system identical to a previously acquired one. This inquiry led to discussions about a larger project requiring additional systems that Flexicon could provide.
Addressing the need for gentle almond handling to prevent unsalable breakage, Flexicon customized a solution featuring six FLEXI-DISC Tubular Cable Conveyors (TCC). These conveyors facilitate the delicate transport of almonds via smooth stainless steel tubes with low-friction polymer discs attached to a steel cable. The system operates through a drive wheel tensioned by another wheel on the opposite end, transporting almonds post-blanching to subsequent processing stages.
The six conveyors were engineered to accommodate specific operational details, incorporating unique horizontal and vertical lengths, angles, material origins, and destinations. Efficient storage during almond pasteurization and blanching is crucial as production rates surpass downstream processing capacities. Flexicon crafted two 12,500 kg-capacity storage hoppers using sanitary construction to securely store almonds awaiting processing.
These hoppers feature a spiral 'let down' chute, ensuring gentle almond descent into storage bins, while vibratory feeders facilitate transfer to TCC lines directed to almond cutter lines. Integrated plant-wide control systems link conveyor systems to upstream and downstream processes. Collaboration with a local controls integrator ensured synchronized operations.
Flexicon's local component inventory reduced downtimes, with immediate parts availability reducing disruption risks. Project Optimise, operational since 2021, increased output by nearly 70% over a seven-month timeline.
"Flexicon's design and drafting were spot on," commented Craig Haskard, Almondco's Group Engineering Project Manager, highlighting seamless installation and commissioning.
Source: Food Technology & Manufacturing
