Tubular cable conveyor system helps to increase production 70% for almond processor

Established in 1944, Almondco Australia is a supplier of high-quality almonds for processors of almond-based products. In late 2020, the company unveiled Project Optimise, a new 10,000 m² structure situated adjacent to its existing processing facility in Renmark, South Australia. This expansion increased the company’s storage capacity for the annual almond crops of its grower members, while also streamlining operations by consolidating multiple processing operations in one spot.

During the planning process for the expansion, Almondco foresaw the need for an effective transportation and storage system for handling high volumes of the fragile, raw and blanched almonds.

The almond supplier had previously partnered with local designer and manufacturer of bulk material handling equipment, Flexicon Australia, as all of its systems are manufactured in Australia, which appealed to Almondco’s Craig Haskard, Group Engineering Project Manager.

“We were looking for a local supplier that can provide ongoing support,” Haskard said. “Flexicon immediately came to mind due to our existing relationship with them, and the success of previous projects. It was a no-brainer to select Flexicon as a partner.”

Rob Wallis, Application Engineering Manager, Flexicon Australia, said Almondco asked for a quote on a new bulk bag filling system, identical to one it had previously purchased. “In the process of quoting him for the filler, it came to light that there was a very large project at Almondco, and they would have a need for some of the other systems that we offer.”

Wallis therefore proposed a comprehensive solution featuring a series of tubular cable conveyors, a bulk bag filler and a pair of large storage hoppers. The processor’s need for a large scale and complex project was met by Flexicon's development of a seamless custom-build aligned with Almondco’s operational needs.

Gentle handling of fragile almonds

To address the critical need for gentle almond handling — essential to prevent breakage or damage that would render the product unsalable — Flexicon specified a six-conveyor system composed entirely of its FLEXI-DISC Tubular Cable Conveyors (TCC).

These conveyors gently transport almonds through smooth stainless steel tubing using low-friction polymer discs attached to a stainless steel cable. The system is powered by a drive wheel at one end of the circuit and maintained under tension by a wheel at the opposite end.

The FLEXI-DISC System gently conveys the fragile whole blanched almonds from the blancher towards downstream processing functions.

With each of the six conveyor lines manufactured to specific operational requirements, including custom horizontal and vertical lengths, multiple angles and distinct material sources and destinations, the versatile system's features were crucial to the success of Almondco’s operations.

High-capacity storage hoppers enable continuous production

Almondco’s pasteurisation and blanching activities produce almonds at a faster rate than the downstream equipment can process them. To safely store the almonds until they can be handled, Flexicon also designed and fabricated a pair of 12,500 kg capacity custom-engineered, sanitary-construction storage hoppers.

Flexicon provided a spiral ‘let down’ chute mounted below the conveyor discharge outlets. Almonds slide down this chute in a helical motion, which slows their descent, preventing them from being damaged as they flow into one of the large storage bins. A vibratory feeder at the base of each hopper feeds the almonds into a TCC that gently feeds them toward the almond cutter line.

In the foreground, a Flexi-Disc System feeds a storage silo, while in the background, filled bulk bags of whole blanched almonds are prepared for shipment to Almondco’s consumer product processors.

Local benefits and impressive results

All six conveyor systems are integrated into a plant-wide control system, creating a seamless connection between upstream and downstream processes. To facilitate this, Flexicon collaborated closely with a local controls integrator, ensuring the systems were synchronised and that the integration was executed smoothly, to enhance overall system performance and reliability.

An additional benefit was Flexicon Australia’s large inventory of replacement components, which alleviated Haskard’s concerns about extended downtimes. With readily available parts stored locally, the risk of delays due to waiting for replacement components to arrive from outside Australia was reduced, ensuring minimal disruption to Almondco’s operations.

Project Optimise delivered impressive results, boosting processing output by nearly 70%. The entire project spanned seven months from start to completion and has been in operation since 2021.

“Flexicon’s design and drafting were spot on,” Haskard said. “All components — from the conveying runs to the frame footplates — were as drawn, enabling installation and commissioning to be completed without any issues or setbacks.”

Top image caption: Craig Haskard, Group Engineering Project Manager, Almondco.