On-site Planning
Installation & Commissioning
Automated & Energy Efficient
Client Name: G****L Food Processing Ltd.
Country: Republic of Ghana
Region: Eastern Region – an important area for plantain and tropical crop cultivation in West Africa
Core Products: Organic plantain slices (fresh slices, frozen semi-finished products, raw material for fried chips)
Equipment Configuration: Hadof custom continuous high-speed slicing line (including fully automatic feeding system, precision thickness adjustment slicing unit, vibrating dewatering and screening module)
Commissioning Date: Q4 2020
Ghana is one of the world's leading plantain producers. Plantain is a staple food and an important raw material for snacks. G****L has been engaged in plantain deep processing since 2015, supplying West African fast-food chains and export markets in Europe. However, for a long time, the slicing process relied on manual handheld knives, which became the primary bottleneck for capacity and quality.
Manual slicing presented multiple challenges:
Low efficiency and high labor costs: During peak seasons, over 40 temporary workers were needed daily, yet orders still could not be fulfilled. High labor turnover led to continuous training expenses.
Inconsistent thickness, low yield: Manual slicing resulted in thickness variations of up to 3-5mm, causing uneven cooking during frying or drying, with reject rates often exceeding 15%, directly affecting export inspection pass rates.
Hygiene risks and certification difficulties: Multiple manual handling steps increased foreign matter risks, making it difficult to meet international food standards such as BRC and IFS, hindering entry into high-end European markets.
High raw material waste: Inconsistent cutting led to significant trimmings, with overall utilization below 80%, severely squeezing profit margins.
To overcome these bottlenecks, Mr. Kojo, head of G****L, began searching globally for automated slicing equipment that could handle tropical crop characteristics while balancing capacity and hygiene standards. After evaluating several suppliers, G****L chose Hadof for its in-depth understanding of plantain properties and its custom design capabilities.
We provided three core custom designs tailored to plantain's high starch content and tendency to oxidize:
1. High-Precision Servo Slicing System
A rotating disc blade combined with a servo-driven feed system allows stepless thickness adjustment from 1mm to 12mm, with deviation controlled within ±0.3mm. This ensures uniform heating during subsequent frying or freezing. The food-grade stainless steel blades are coated with Teflon to minimize starch sticking, maintaining sharpness and stability for over 4 hours of continuous operation.
2. Hygienic Fully Enclosed Structure
The entire line is made of 304 stainless steel, with all contact surfaces designed with rounded corners and no dead spaces. Online CIP cleaning connections are included. The equipment meets CE and US FDA hygiene standards, preventing cross-contamination. Air curtains and quick-release components further satisfy strict cleanliness requirements from international buyers.
3. Flexible Conveying & Intelligent Sorting Integration
The slicing outlet feeds directly into a vibrating sorter that automatically removes crumbs and irregular pieces. Qualified slices proceed to blanching or freezing. The entire line is controlled by a PLC, monitoring slicing speed, thickness, and equipment status in real time. One technician can manage the entire line, significantly reducing reliance on skilled labor.
Client Testimonial: From Regional Processing to Global Supply Chain
Since the new line was fully operational in early 2021, G****L's performance has transformed:
Capacity & Efficiency Gains
Daily fresh plantain processing: increased from 3 tons/day with manual cutting to 15 tons/day (single 8-hour shift), reaching up to 28 tons/day with two shifts during peak periods, reducing order lead times by 60%.
Workforce: Slicing operators reduced from 40 to 6, cutting labor costs by about 75%, while new employee training time dropped from two weeks to one day.
Quality & Market Expansion
Yield rate: Thickness uniformity improved, raising the premium rate for fried chips from 78% to 96%, significantly reducing reject losses.
International certification: Achieved BRC Global Standard for Food Safety Grade A in 2021, successfully entering the supply chains of major supermarket chains in the UK and the Netherlands, with export volume growing 120% annually for two consecutive years.
Resource Optimization
Overall utilization: Precision slicing and automatic separation of crumbs increased raw material utilization from 82% to 94%, saving over $180,000 annually in raw material costs.
Energy consumption: All motors are IE3 high-efficiency class, reducing electricity consumption per unit output by 22% compared to traditional separate equipment.
"We used to think that industrial slicing would compromise the traditional texture of plantain. Hadof's team showed us that truly good equipment respects the raw material – it preserves the natural fiber structure and color of the plantain while giving us a ticket to developed markets. This is not just an equipment upgrade; it's a rebirth of our competitiveness."
—— G****L Food Processing Ltd., Technical Director Mr. Kojo
