Repurposing a Salad Line for Higher Capacity Without Disrupting Production

When a leading UK supplier of prepared salads and vegetables needed to increase capacity for a new product range, they turned to Lingwood. The challenge was significant: repurpose an underutilised production line to achieve higher throughput, without halting day-to-day operations. The result was a fully integrated washing and drying line capable of processing 1,400kg per hour, delivered on time and with zero production downtime.

The Challenge: Higher Throughput Without Downtime

Repurposing an existing production line is a cost-effective alternative to building new capacity from scratch. However, it presents a unique set of food processing challenges. For this project, the key requirements were:

• Throughput: Achieve a processing capacity of 1,400kg per hour.
• Wash quality: Ensure thorough cleaning and reliable removal of foreign bodies.
• Water management: Maintain efficient water usage throughout the process.
• Product quality: Deliver damage-free produce with the correct moisture levels and optimal shelf life.

Critically, the upgrade involved removing outdated equipment, installing new machinery, and updating control systems, all while the factory remained fully operational. Any disruption to production would directly impact the supplier’s ability to meet customer demand.

The Solution: Bespoke Vegetable Washing and Drying Line

Drawing on more than 25 years of experience in the food processing industry, Lingwood worked closely with the customer to design a tailored solution. Our collaborative, in-house approach ensured every element was matched to the supplier’s exact requirements.

The project included:

• Validated equipment trials: Comprehensive testing to confirm both capacity and quality targets could be met before installation.
• New processing components: Including trimming stations, a GEWA 4000 flume washer, and a K850 centrifuge dryer for efficient, high-quality results.
• Seamless integration: Existing slicing equipment was incorporated into the upgraded system, maximising the value of the customer’s current assets.

A detailed action plan governed every stage of the project, from pre-delivery inspections through to installation, commissioning, operator training, and site acceptance testing. This meticulous planning ensured a smooth transition with no interruption to production.

The Results: 1,400kg Per Hour, Delivered On Time

The upgraded line met every objective. It now processes up to 1,400kg per hour, with no disruption to factory operations during installation. Delivered on schedule and within budget, the solution gave the customer a reliable, cost-effective way to expand both capacity and product range.

Key outcomes included:

• Increased capacity to 1,400kg per hour on a previously underutilised line.
• Zero production downtime throughout the upgrade.
• On-time delivery, minimising operational impact, and supporting business growth.

Why Repurpose a Production Line?

Repurposing an existing line delivered substantial cost savings compared to investing in entirely new infrastructure, while still achieving higher capacity and supporting an expanded product range. Lingwood’s expertise, precise planning, and commitment to on-time delivery ensured a seamless transition from start to finish. With lifetime support and spares included, the customer is assured of dependable, long-term performance.

Discuss Your Production Line Upgrade with Lingwood

Looking to increase capacity, improve efficiency, or expand your product range without disrupting production? Lingwood designs and delivers bespoke food processing solutions tailored to your exact needs. Contact us today to discuss your project or arrange a visit to our demonstration facility in Suffolk.

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Efficient washing of whole or halved products using cleaning agents with the GEWA 4000 V RT

Customising and adapting machines to a customer´s special processing requirements is one of KRONEN´s key competencies. By integrating a retention time function in the GEWA 4000V RT (RT stands for “Retention Time”) KRONEN has optimised the requirements of customers who process whole or halved products. Currently a second GEWA 4000V RT has been completed and delivered within just a few months.

This washing machine has a time controlled retaining flap which automatically controls the retention time of the products in the wash tank. This means when using cleaning agents, the fully adjustable contact time a product has with water can be guaranteed. This is a fundamental step for hygiene in further processing.

To facilitate the ideal washing process the product is weighed before it is fed into the machine to ensure that always the same quantity is processed. This avoids overfilling the tank which would hinder a thorough wash-cycle. Simultaneously it ensures an efficient, continual use of the machine. For example, up to 500 kg courgettes, halved peppers or peeled onions can be washed per hour. The cleated belt enables smooth product infeed particularly for whole or bigger products or product pieces.

The further development of the GEWA 4000V enhances the range of GEWA washing machines which process whole products or larger product pieces with the aid of cleaning agents. Any of the washing machines from the GEWA series can be equipped with the RT adjustable retention time function. Currently two GEWA 4000V RT machines are delivering perfect washing results in the production of two customers in the convenience and food service sector.

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