Our friends at A&B Costanza Farms in Sodus, Michigan recently asked us to help them design and build a new packing line for bell peppers. They wanted a line that would handle greater volume with better protection for their valuable crop. They were also hoping to reduce the number of people required to operate the line, even as they packed more product.

Challenge accepted.

Exeter Engineering worked with A&B Costanza Farms to understand their concerns and identify solutions to those problems that would fit into their budget and physical constraints. The result is a bell pepper line that delivers volumes of more than 45,000 lbs per hour with 30% fewer personnel and far less damage to their product than other lines.

The line centers on Exeter Engineering’s Sidewinder sorter, powered by our ID Technology AI-powered optical grading suite. ID Technology takes advantage of Sidewinder’s spinning presentation system to use its high definition cameras and custom-tuned LED lighting to capture superior imagery of every facet of each piece of product. Better imagery means better grading results, especially using our AI-powered grading features. The system sorts into three separate grades. It quickly identifies the presence and severity of discoloration (sun tan), shape, squatty defects, surface punctures, scarring and machine damage, grading each bell pepper by size, color, weight, external grade and overall shape.

The line also features:

• An XTR 500 Zone Dumper to receive the bell peppers into the line (and automatically clean the bins they arrive in for quick re-use!);
• An XTR 100 4-belt EvenFlow Accumulator to regulate the volume of product in the line, keeping it moving at a steady volume; and
• AccuCount Fillers, to automatically fill cartons with graded product…gently and without additional staff

The resulting line is a huge success. A&B Costanza farms has reduced their overhead while also increasing the quality of the product leaving their facilities. The flexibility of the ID Technology system also offers them the ability to quickly and easily respond to the market, increasing their bottom line without increasing their headcount.

If you’re thinking about adding or upgrading your packing solutions, contact the fresh produce packing experts at Exeter Engineering. Common sense engineering married with cutting edge technology since 1978.