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Harversters
MPS has designed a harvestor for AFRICA, it is robust in design and equipped to accommodate our traditional ‘plukkiste’ . We have plenty of harvestors in the field.
The plastic pickup wheels can be sourced from MPS as they own the mould and manufacturing rights. Contact us for information regarding their capacity.
The first step to ‘Automation ‘ of harvesting is at hand. Cost savings realised by labour saving devices can be utilised to improve husking plants.
Kernal Processing – Pre-Drying
The intake of WNIS is dependent on the volumes that processors receive per day. At Macridge the intake is either into bins mounted on load cells or over a weigh bridge. Bulk bins, bulk bags, crates and polyprop bags are all accomodated .
The elevators and conveyors at MPS have been standardised after extensive field trials. The MODULAR concept has been adopted for section lengths and widths. This reduces raw material wastage. Added advantages are, NO welding and grinding and MPS is able to assemble and test units on their premises before dissasembly and transportation.
Conveyors are easily constructed and assembled due to no welding, no painting and standardization of components.
Long term benefits are that the galvanized sheeting does not require periodic painting as is the case with mild steel units.
Drying bins are similar in construction to the conveyors and elevators, in that :
- The material used is also galvanized plate. Plenum chambers are clear view galvanized fencing which allows for increased air flow.
- Easy let downs are constructed with rubber steps to reduce noise. The fan units are mounted on swing doors which is ideal for access to the plenum chamber and for maintenance.
Kernal Processing – Sorting
MPS have built kernel sorting conveyors complete with light fixtures , vibrator feeders for volume control and hangers for ancilary tools. The product that is removed is placed via chutes into crates slung below the conveyor on rails. The conveyors can be manufactured in modular form or as solid units as the client prefers.
Ring polish is not used in the new generation equipment, rather the stainless is polished to a smooth surface that assists to keep clean and contamination free.
MPS have used vibrator motors to manufacture feeders for all applications. These units are cost effective and can be adjusted to increase the vibratory action. When coupled with VSD drives they allow for product flow control to a fine degree. Vibratory motors are also used in the sieveing of product when fitted with screens, these are also adjustable for vibration action and feed control.
MPS takes hygiene and ease of cleaning into consideration in all equipment, we constantly re-engineer equipment to meet with food safety standards.
Kernal – Pre Drying
Kernel that has been sorted from shell normally has a Moisture Content of between 2,5 and 1,8%. The moisture has to be reduced to SAMAC STANDARDS that are also internationally accepted. Macridge has opted to dry their kernel on trays normally associated with the dry fruit industry.
This innovative concept allows for much quicker drying time. The kernel is spread thinly on the trays that are perforated allowing excellent air flow. Each pair of foursome of trolleys are allocated to an individual drying cubicle which allows for stock control and movement to be monitored.
Trays that have been used have to be cleaned and sanitised and this is done in the custom designed trough that allows manual scrubbing and individual inspection of all trays before reuse. The tank comparments can be individually drained and refilled. Up to four washers can use this system at a time.
The trolleys used for the drying trays are of simple design but able to hold up to 33 trays each (Tray design maximum stack level) when full. The tray designer has considered the stacking aspect and allowed for the trays to be able to wedge top to bottom for stability.
The trolley is maneuverable and can be manipulated by one person.
This ease of handling reduces labour, injury and product loss.
The well designed tray filler and sanitizer was used when Macridge was a ‘wet’ system operation. The kernel to be trayed is placed in the hopper and a shaker will spread the product thinly over the sieve, spray nozzles apply a sanitizer.
The ‘tray’ is located on rollers and fed along the bottom of the shaker allowing kernel to be spread evenly onto it. This prevents operator ‘hand and utensil’ contamination. Drip trays and tanks collect the sanitizer run-off below the unit.
Dehusking
The MPS harvestors allow for greater volumes and faster harvesting. MACRIDGE has moved to Bulk crates in the orchards to collect the WNIH and these are emptied into bulk bins via our CRATE TIPPERS.
The bulk crates are loaded into the tippers and emptied in minutes allowing the bulk crate to be returned to the orchard with the same transport. Labour saving by fast turnarounds is accomplished.
Custom made WNIH bins of various capacities can be designed to meet the farmers needs.
We explore options when we are invited to dehusking plants. With the easy to use design programmes used by MPS the need to modify existing buildings may not be necessary. Possible cost savings can be achieved by utilizing existing infrastructures.
MPS elevators and conveyors are unique, in that, they are modular in design. This concept has several advantages:
- Easily transportable as ‘Flat packs’ / Semi skilled labour can do the assembly / Sections can be added or removed as circumstances change/ Welding and drilling is eliminated.
- We utilise Galvanised plate in most applications.
MPS modular elevators and conveyors are designed to utilise as much raw material as possible (Sheet metal) This is possible with our design programmes. The advantage is less waste and costs. MPS will advise on which dimensions are most popular.
The harvestors although brilliant in design cannot differentiate between stones, sticks leaves and Nut in shell.
However the orchard debris can all be removed with the use of MPS Spiral Cleaners. The spirals allow the WNIH to be singulated and revolved as they travel along the spiral roller. All unwanted foreign material is shed through the spiral roller gaps. The dehusker only recieves NIH. An addded advantage is that the orchard debris is reduced.
What a BIG difference it makes!!
The heart of a Macadamia Farm is the Dehusking unit.
Great emphasis is placed on the apperance of the shell for asthetic purposes in the NIS export market. Coupled with this is the need to reduce breakage of NIS. The MPS Husker meets this criteria. The huskers can be manufactured in 2, 3, or 4, lane configurations. MPS has strived to enable the farmer to make repairs to their dehuskers, the ‘lanes’ can be easily removed as can the inlet ‘shoes’ .
MPS tumbler Rod spaceing is very accurate. The use of CNC cut rims ensures their alignment is precise.
The tumblers are used to remove Orchard debris (Similar to the Spiral cleaner) or to remove the undersize WNIS after dehusking. Any left over husk from the dehusk action is also removed during this process.
MPS Sorting conveyors or tables are equipped with division lanes to allow the pickers to place reject product into. The lanes empty on the conveyor end, on the left and right into crates and the ‘good’ product in the middel into separate crates.
The conveyor speed can be set to allow for slower speed when necessary or to speed up the transfer when product is of good quality.
Conveyors are modular designed, galvanised sheeting is used to reduce maintenance costs.
Kernal Processing – Cracking
The Macadamia industry calculates kernel recovery and moisture loss through weight comparisons of the incoming Wet Nut In Shell and the Dry Nut In Shell weights. This important comparison is the base of farmer payments. MPS constructs weigh bins that allow the inclusion of load cells. These can be of different capacity and are essential to the industry..
Conveyors that are designed to convey the Macadamia nuts before and after cracking are modular, use the correct grade of belting and we attempt to reduce spillage by designing the conveyors with tieups, chutes and transfers that will work through gravity. The angle of discharge is important in this regard. Modular, galvanised or stainless steel MPS has the experience to advise which option to choose.
Elevators are well known spillage points, mainly due to factors such as volume, elevation angle, belt speed and transfers. The MPS elevators are modular and we consider all factors to manufacture units that take these problems into consideration.
In some instances use is made of augers to transfer NIS. This is not a preferred method due to hygiene aspects but MPS will accept the challenge and construct units that are easier to maintain and keep clean. Our credo is finding solutions, it is a challenge we accept.
MPS has developed an alternative to the expensive imported electro magnet vibrator feeders currently being used.
We construct vibrator pans utilising off-the-shelf parts and at a fraction of the cost.
The MPS vibrator feeders are used in many applications, Crackers, Nut in Shell feeders and kernel feeders.
When used with a VSD the vibrator is able to operate at similar feed rates as that of the conventional feeders.
MPS has designed a roller cracker that is continually being refined. We have well over twenty operational in the field and the first one built is still the only cracker at Macridge after 8 years.
The MPS cracker advantages are: Robust, made in South Africa, availabilty of spares and backup, adjustable to varying cultivar nut types, low maintenance and downtime and its capacity. (Throughput)
With pre- sized DNIS the recovery of whole kernel is equal to other crackers being used, its biggest advantage is less kernel fines and higher kernel recovery as a result.
Introducing the M.P.S MINI ROLLER CRACKER, inspired by our successful commercial roller cracker that has established itself in the macadamia market over the last 12 years with multiple units sold globally.
M.P.S can FINALLY offer that same reliability and efficiency of our commercial roller cracker, JAM PACKED into the smallest possible footprint of only 660mm L x 500mm W x 730mm W. Without compromising on any essential components that has cemented our commercial roller cracker’s success in the macadamia market.
Our MINI ROLLER CRACKER comes equipped with a vibratory hopper feeder with a +/- 5 kg hopper capacity, fully adjustable pre-sizer that can accommodate all sizes ranging from 16mm – 30 mm, and fully adjustable cracking rolls with linear indicators that can be set to optimise on kernel recovery with minimal “NO CRACKS/RE-RUNS”, boasting an impressive cracking capacity of 180 kg p/h for this tiny footprint.
The M.P.S MINI ROLLER CRACKER is powered by a 0,55kw motor and are available in both single and 3 phase power supply. All of the above mentioned at a PRICE TAG that suits the pocket just right.
MPS has taken the Spiral Roller concept, where product is SINGULATED and utilised it in many different areas.
The Spiral roller gaps are adjustable which allows kernel to be graded according to size. This method is soft on kernel and provided the feed rate is kept within specification is very effective in the recovery of ALL whole kernel.
The wholes and halves seperation of kernel using MPS equipment has entered a new phase in the processing field. The concern of damaging kernel with vibrator sieves, tumblers (Trommels) and similar means has been identified.
The first step in the ‘soft approach’ to kernel is the incline belt roll out system developed. Whole Kernel fed onto the inclined belt at the correct volume, using the correct belt speed, will roll out in the opposite end to the belts running direction.
Broken and half kernel will settle onto their ‘flat’ sides and be conveyed up.
Packing
MPS staff have the background which allows us to design complete packing lines for kernel. In particular the hygenic options are considered and this is reflected in the use of staionless steel hoppers and ancillary equipment. We are focusing on the need for quick clean equipment that is accessable to staff and limits safety hazards.
Installations, roller conveyors, carton form stands, impact shakers, and seal/tape stations are all manufactured at MPS.
- An MPS Packing elevator in action, the new generation lines will have covers to limit foreign material, dust and similar atmospheric contaminents.
- Spillage points are addressed and eliminated, while use can also be made of proximity sensors to semi- automate filling lines.
The STYLES of kernel can be challening, especially the ‘mix’ of wholes and halves. The solution to this problem could be multiple hoppers that operate on the basis of weight to ensure the correct quantity of different kernel sizes is pre-weighed.
The blending of the two to achieve a homogenous mix is also critical, vibrator feeders are utilised in this role to simultaneously feed the two lines into the packing elevator.
MPS has retro-fitted metal detectors to packing lines, this CCP must be designed and incorporated correctly as it is critical to factory Quality Standards and controls. Manually operated Weighing stations can be partially automated to increase labour effeciency. An area overlooked in many factories is the cleaning of the scale stand and scale. This is adressed through simple stands in stainless steel with scales quickly removed and returned after cleaning is completed.
Carton shakers compact the carton contents allowing the closure to be effective. In particular the carton shape retention is critical as any carton side wall bulge will impact on container loading. Use is made of carton moulds that ensures the cartons shape integrity is maintained.
The shaker can be fitted with timers to limit the impact duration and reduce ‘clumping’ or oil bleed of the contents.
Accuracy of application (Tape, labels, stamps and signage) reflects the care that factories take in their packing lines. Any distorted or skew applications is immediately noticeable.
MPS have designed a tape applicator that goes a long way to addressing this!
Value Adding
MPS have been involved in the procurement of oil extraction equipment and are able to supply the ancillary equipment that is needed for a COLD PRESSED oil extraction system.
Augers and hoppers can be designed in both Mild Steel or Stainless Steel. The homogenous mixing of raw materials and their conveyance to oil presses has been achieved through practical experience.
MPS understands the COLD PRESSED OIL EXTRACTION process and are able to assist with the cost effective procurement of a procesing line. Macadamia oil equipment can be sourced from alternative industries to be combined into effective process units. This can only be achieved through years of practical experience.
The kernel meal and shell and non conforming kernel that is part of the cracking process can be converted to a high end product generating its own income stream.
MPS’s Practical advice Based on experience allows any Macadamia processor to use the Kernel by-products and create a high end consumer product.
We can design effective low cost bottlling lines that will meet quality standards.
Meet our Team
MPS, is about Quality first, we understand the pressures that both farmers and processors are subjected to by market forces. Accreditation bodies for management and quality systems all have strict standards to be implemented by the Farmer and the Processor to enable them to market their produce.