Leading UK Food Manufacturer Automates Bell Pepper Processing with Lingwood

Executive Summary

A leading UK food manufacturer faced ongoing challenges with labour-intensive, manual bell pepper processing, resulting in inconsistent product quality, safety risks, and high operational costs. Lingwood delivered a fully automated Robot Pepper line, equipped with advanced AI vision systems, to transform the entire process. The solution reduced labour costs, improved product yield, guaranteed daily output, and maximised processing efficiency, demonstrating the value of automated food processing machinery in a competitive market.

The Challenge: Manual Pepper Processing Limitations

Before partnering with Lingwood, the manufacturer relied on a manual process in which staff cored and cut bell peppers by hand using knives. This approach created several significant problems:

• Labour-intensive operations: Processing required a large workforce, increasing wage costs and scheduling complexity.
• Inconsistent product quality: Output depended heavily on individual operator skill, leading to variable results and increased waste.
• Safety risks: Manual cutting exposes staff to injuries and repetitive strain, raising health and safety concerns.

The client needed a reliable, cost-effective food processing solution that would improve yield, reduce dependency on manual labour, and deliver consistent product quality.

The Solution: Lingwood’s Automated Robot Pepper Line

Drawing on more than 25 years of food processing expertise, Lingwood supplied a fully automated Robot Pepper line capable of processing up to 5,400 peppers per hour. The system combines robotics and intelligent vision technology to deliver precise, repeatable results:

• AI Vision Systems: Each pepper is scanned to accurately determine its size and shape, ensuring optimal processing.
• Robotic Automation: Robots handle and transfer peppers with precision, removing the need for manual handling.
• Customisable Processing: Processing units automatically adjust to each pepper’s dimensions, removing cores and cutting with consistent accuracy.

This tailored solution was designed to integrate seamlessly with the manufacturer’s existing production line, minimising disruption and ensuring a smooth transition from manual to automated operations.

The Results: Measurable Efficiency and Cost Savings

The installation of Lingwood’s Robot Pepper line delivered immediate, measurable benefits:

• Reduced labour costs: The automated line removed the need for 6 operators per shift, freeing staff for higher-value tasks.
• Higher product yield: Precise cutting maximised usable product and lowered raw material costs.
• Guaranteed daily output: Consistent, automated processing ensured reliable production volumes every day.
• Lower operational costs: Reduced working hours and improved efficiency cut overall running costs.
• Improved safety: Removing manual knife work eliminated the risk of cuts and repetitive strain injuries.

Conclusion

By replacing a manual, labour-intensive process with an intelligent automated system, Lingwood helped this leading UK food manufacturer improve safety, reduce costs, and enhance overall efficiency. The Robot Pepper line provides a scalable, reliable solution built to support long-term productivity, backed by Lingwood’s commitment to lifetime support and proven track record across the UK and Ireland.

Ready to transform your processing line? Contact Lingwood today to discover how our automated food processing solutions can be tailored to your exact needs.

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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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