By Midge Munro – Group Communications and Marketing Manager, Darling Group.
Darling Group’s Just Avocados packhouse in Katikati has undergone significant change and physical transformation in the past 8 months with the commissioning of a new state-of-the-art avocado handling and sorting machine. The new system has enabled the company to drastically increase their throughput and labour efficiency.
The new machine, sourced from France, is a MAF RODA Pomone 2 lane sizer. Just Avocados have been running the machine since the beginning of the 2022-23 avocado season.
Just Avocados business manager Jonathan Baker says the system is unique to Just Avocados as many other setups in the Bay of Plenty are designed for kiwifruit first and foremost and are then altered to suit the avocado season.
“Our machine is purpose built and dedicated for avocados all year round.
“We are the only pack house with a water bath in the bin tip area which is like a presoak that helps to loosen any debris on the avocados before they pass through the water blaster.”
The introduction of a camera grading system (Global scan 7) has increased efficiency versus the previous hand grading and guarantees consistency of grading.
The new machine was estimated to give Just Avocados up to a 65% increase in efficiency, Jonathan says the machine has exceeded this with throughput increasing by 73%.
“With the addition of more drops we can also now pack class 3 at the same time as Class 1 and 2 and avoid retipping.
“Labour efficiency has also improved but it is possible to make further gains.”
While the technology has removed a significant portion of human interaction in the handling and sorting process Jonathan says staff levels have remained the same.
“With training, we have been able to redeploy our staff within the shed to fit the new process.
“We do still require a few manual graders but have increased the number of tray prep and packers. We have also increased our full-time quality and production team to ensure we are resilient and have a wider range of skills in house.
“The new line has also assisted in the packing process being more composed and systematic and as a result has helped alleviate staff issues around fatigue.
Grower reaction to the upgraded facility has been positive.
“Although the class 1 percentage packouts have been lower this season than what most growers were hoping for, seeing the line and operation running has given confidence to them that we are trying to maximise their returns.”
Major site developments were also undertaken to accommodate a redesigned workflow.
“A new inwards yarding area had to be constructed, offices were relocated, additional building expansion was completed, significant electrical and plumbing services were installed.”
Work is ongoing, with new additional office space being located on site and loading bays still under development which will eventually include the ability to load export product directly into containers through a dedicated temperature-controlled loading dock.
Just Avocados’ refitted packhouse will be on display during the World Avocado Congress in April. Darling Group is the major New Zealand sponsor of this international event which promises to be an exciting way to engage with the latest information on the science, marketing, and growing of avocados while being in a fun environment surrounded by passionate members of the global avocado industry. Specially priced registrations are still available for growers – head to www.wacnz2023.com and register with your PPIN.