Line for sweet corn processing

Описание: The line is intended for preparing harvested sweet corn for packaging.
The process consists of length calibration, removal of chaff and hair, washing, inspection and packaging.

The line’s capacity is about 3000 cobs (ears of corn) per hour. The line’s throughput and intensity of the work can be changed in any moment by turning a knob for adjusting dosing speed.

Elements of the line:

It consists of a input unit (a pallet box tipper or a belt conveyor of a larger capacity), a buffer conveyor, an inclined conveyor for dosing, a belt conveyor for providing corn to workers, a platform for workers, a holding belt conveyor that leads to the calibrator, the calibrator for cutting off the top and the bottom of the cob, a corn husker with pre-washing, a hair cleaner with final washing, a revison conveyor and a control cabinet.

Description of work and process:

According to the customer's choice, there are two options how to handle corn on the beginning of the line: using the pallet box tipper or the belt conveyor of a larger capacity.

In a first option, a pallet box is placed on the hydraulic tipper by means of a forklift. The tipper is then precisely controlled with a joystick from a place on a platform where a worker has a clear sight. Tipper drops corn into the receiving buffer conveyor.
In a second option, corn is placed onto a larger belt conveyor by whichever means possible. This belt conveyor with volume capacity of 3 m3 is sturdy enough to receive the corn and to transport it to the same buffer conveyor as in the first option.

From thereon, the process remains the same.

The receiving buffer conveyor takes the corn to the inclined belt conveyor, which uniformly doses the corn. Dosing speed can be easily adjusted in any moment with the control knob at workers fingertips. Corn gently falls to the conveyor that supplies the workers. The workers take the corn ears (cobs) from it and place them on the conveyor according to the laser beam, which marks the cutting position of the lower part of the ear (cob). The length of the ear (cob) is determined by positioning the distance between the cutting knives and can be adjusted from 130-230 mm depending on the size of the ear (cob). After cutting, the corn goes to the husker, where the husk and part of the hair is removed.

The corn husker is equipped with a pre-wash system that also facilitates husk removal, especially in earlier harvests.
The corn husker roller coating is made of a material whose hardness corresponds to the processing of sweet corn and does not damage the corn, while successfully removing husk.
With removed husk, the corn enters the machine for brushing and washing, where the hairs are removed and ear (cob) finally cleaned.
Corn then ends on the revision conveyor where it is manually picked and placed in the dedicated packaging.

Final packaging can be done elsewhere or in near proximity of the line.

The electrical cabinet has an HMI with intuitive display of the whole line. Line is easily started and put in operation as well as shut down. Every part of the line can be manually started via HMI. All status information are also displayed.

The line can be arranged in flat or L form – depending on the customer’s request. In both cases every machine is easily accessible by a forklift. Waste receptacles are therefore easily replaced. Water from washing machines can be simply led from the tubs to a drain using a hose.

Dimensions of the line in L form:
Length: 9200 mm
Width: 6200 mm
Height: 2600 mm