• Material Feeding &Waste Removal
Material Feeding and Waste Removal: A Seamless Process:
The first crucial step in our packing house is the efficient feeding of fresh produce and the removal of waste. To achieve this, we have implemented a sophisticated conveyor system that consists of eight supply lines and eight removal lines. The supply lines are designed to ensure a continuous flow of produce, always remaining full. These lines are equipped with motorized sections, the specific length of which will be determined by the supplier. For added control, manual start-stop controls are strategically placed at the feed-end of each conveyor. Safety is paramount, and we have taken measures to ensure the well-being of our workers. Safety covers are installed on all rotating parts and potential pinch points, minimizing the risk of accidents. Beneath the supply lines, the removal lines efficiently transport waste and empty plastic crates in the opposite direction. These lines are positioned at an ergonomically suitable height to facilitate easy handling and reduce strain on workers. At the end of the removal lines, a clever design automatically transfers the plastic crates onto two conveyors that run perpendicular to the primary removal lines. These conveyors transport the crates to the waste recovery and plastic crate washing facilities located outside the packing house. To accommodate our waste management needs, we have installed two separate waste recovery and plastic crate washing facilities on the exterior of the packing house. The washing system is designed to automatically turn the crates upside down, allowing waste products to be dumped into a chute and collected in a waste bin. Clean crates are then fed into the washing chamber for thorough cleaning. This efficient material feeding and waste removal system ensures a smooth and uninterrupted flow of produce throughout our packing house. By prioritizing safety, efficiency, and sustainability, we are able to optimize our operations and deliver the highest quality products to our customers.

• Grading, Scaling, Packing, and Weighing
The heart of our packing house lies in the grading, scaling, packing, and weighing stations. These stations are meticulously designed to ensure the highest quality and accuracy in our operations. Our facility features four packing lines, each equipped with 24 primary packing stations. This translates to a total of 192 packing stations, providing ample capacity to handle our diverse range of produce. Each packing station is comprised of a separate scale table and grading table, allowing for precise measurements and quality control. To optimize efficiency, one or two workers are assigned to operate a single table station. The supplier will provide detailed specifications for the working surface dimensions, which typically measure 610mm deep and 1861mm wide. Ergonomics is a priority, and we have ensured that the working surface height is adjustable within a 100mm range. This allows workers to find the most comfortable position, reducing strain and fatigue. The tables are equipped with side shelves for convenient storage of plastic crates with fresh produce. Underneath the working surface, a holding shelf collects waste products, while the remaining space is utilized for storage of essential packaging materials such as punnets and carry bags. A gutter section channels waste towards a chute, directing it into the waste-collecting plastic crate. To enhance productivity and organization, the table frames feature prefabricated holes for securing small tools like scissors and other necessary items. This ensures that workers have everything they need within easy reach. With these well-designed packing stations, our team can efficiently grade, scale, pack, and weigh our produce, ensuring that every product meets our stringent quality standards.

• Types Of Packing
1. Conventional Cartons
Packing: A Tailored Approach for Different Produce:
Our packing process is designed to accommodate various types of produce and packaging requirements. We offer two primary packing methods: conventional cartons and punnets. Conventional cartons are ideal for bulkier produce. After grading and weighing, the produce is manually placed into cartons and transported via a conveyor to the final checking and closing stations. For conventional cartons, the final checking and closing process takes place directly at the closing table, eliminating the need for additional conveyors. After the cartons are closed, they are manually carried to a conveyor that feeds them to the palletizing area. In some cases, this conveyor may be shared by multiple closing stations to optimize efficiency.

2. Punnets
Punnets, on the other hand, are suitable for smaller, delicate items. These are placed onto a specialized conveyor that runs on a loop route alongside the carton conveyor. Punnets pass through a check-weigher and labeler before reaching the final packing stations. At the final packing stations, individual punnets are carefully removed from the conveyor and packed into different weight-sized cartons. These cartons are then manually carried to a closing table where the final packaging materials are inserted and the cartons are sealed. By offering both conventional cartons and punnets, we can accommodate a wide range of produce and customer preferences, ensuring that our products are packaged in the most suitable manner.

• Closing& Palletizing
Closing and Palletizing: The Final Stage of Packaging:
The final stage of our packaging process involves closing the cartons and preparing them for shipment. We have established 16 closing tables per packing line, resulting in a total of 64 closing tables across our facility. These tables are strategically located at the end of the packed product feed lines. The closing tables are designed for efficient manual handling of cartons. They have a height of 850mm, while the depth will be determined by the supplier based on industry best practices. The length of each table is approximately 2,500mm. To ensure a well-organized workspace, shelves are positioned below all tables for the storage of packaging materials. This keeps everything within easy reach and minimizes clutter. Once the cartons are closed, they are manually carried to the palletizing feed conveyors. We have 8 conveyors dedicated to conventional cartons, each measuring approximately 20 meters in length. Similarly, we have 8 conveyors for punnet cartons, also measuring 20 meters each. Both types of conveyors have a roller height of 850mm for smooth transportation. This efficient closing and palletizing process ensures that our products are packaged securely and ready for shipment. The well-designed tables and conveyors facilitate smooth operations and minimize manual handling, contributing to overall productivity.