On-site Planning
Installation & Commissioning
Automated & Energy Efficient
Client Name: A****P Polska Sp. z o.o.
Country: Republic of Poland
Region: Masovian Voivodeship – a major apple growing area in Europe
Core Products: Fresh-cut apple slices (ready-to-eat snacks), frozen apple dices, dried fruit raw material, apple rings for baking
Equipment Configuration: Hadof custom high-speed apple slicing line (including automatic feeding and washing unit, coring and slicing integrated machine, intelligent color sorting, and anti-oxidation treatment module)
Commissioning Date: Q3 2019
Poland is one of Europe's leading apple producers, with an annual output exceeding 4 million tons, of which about 30% is used for deep processing. A****P, located in the Masovian Voivodeship, had been engaged in apple sorting and fresh fruit export since 2010. However, with the rapid expansion of the ready-to-eat fruit and vegetable and frozen food markets in Europe, the company decided to move into deep processing. Traditional manual slicing could no longer meet industrial demands.
The challenges in apple slicing were particularly prominent:
Significant capacity bottleneck: During peak season, over 30 tons of fresh fruit needed to be processed daily. Manual slicing required hundreds of workers in shifts, yet still could not meet customer orders, and labor recruitment was difficult.
Inconsistent slice specifications: Manual slicing caused large thickness variations, leading to unstable quality in subsequent freeze-dried or fried products, resulting in increased customer complaints.
Severe oxidation discoloration: Apple slices exposed to air quickly browned. Manual handling could not apply protective treatments quickly, harming product appearance and causing losses as high as 12%.
Foreign matter risk: Manual handling introduced hazards such as hair and fibers, making it difficult to pass strict audits from major European retailers.
After evaluating several equipment suppliers, A****P ultimately chose Hadof as its partner. Based on the characteristics of apples – high moisture, easy oxidation, and diverse specifications – we provided a complete solution:
1. Fully Automatic Coring and Slicing Integrated Design
A customized coring and slicing unit was used, first positioning and coring, then slicing according to set thickness (adjustable from 2mm to 10mm). The blades, made with high-precision laser cutting, ensured a smooth slice surface. The machine speed could match the front-end washing and grading line, enabling continuous operation.
2. Online Anti-Oxidation and Color Protection System
An atomizing spray device was installed at the slicing outlet to automatically apply a food-grade ascorbic acid solution, quickly inhibiting browning. The slices then moved to a dewatering vibrating screen to remove excess moisture, ensuring bright color and extending shelf life by more than 30%.
3. Intelligent Color Sorting and Foreign Matter Removal
A high-definition vision sorter was installed to automatically identify and reject browned slices, spoiled pieces, and foreign materials, achieving sorting accuracy up to 99.7%. The entire line operated in a closed environment to avoid secondary contamination, meeting IFS international food standards.
4. Flexible Downstream Adaptation
The slicing outlet could be flexibly connected to a freezing tunnel, dryer, or vacuum packaging machine, allowing one machine to handle different orders. The whole line was controlled by a PLC, with key data uploaded in real-time for production management and traceability.
Client Testimonial: From Fresh Fruit Supplier to Leading European Deep-Processing Enterprise
Since the new line began operation in 2019, A****P has achieved remarkable growth:
Capacity & Efficiency
Daily fresh fruit processing capacity: increased from less than 10 tons with manual slicing to 40 tons per shift (single shift), reaching 70 tons per day during peak double-shift periods, making it one of the top three apple deep-processing companies in Poland.
Labor optimization: The slicing workforce was reduced from 120 to 8 technicians, cutting labor costs by 85% and eliminating seasonal labor shortages.
Quality & Market
Product qualification rate: Thickness uniformity improved to over 98%, and oxidation discoloration rate dropped from 12% to below 2%, resulting in superior appearance and texture, well received by major customers in Germany, the Netherlands, and elsewhere.
Market expansion: Successfully entered the ready-to-eat fruit and vegetable supply chains of European supermarket chains such as Lidl and Aldi, with export volume growing by 200% over three years.
Overall Benefits
Raw material utilization: Through precision slicing and intelligent rejection, overall raw material utilization increased from 82% to 95%, saving over �400,000 in raw material costs annually.
Energy optimization: The line uses high-efficiency variable-frequency motors, reducing electricity consumption per unit output by 20% compared to traditional separate units, earning EU green agriculture subsidies.
"Hadof's slicing line has truly standardized our apples from field to shelf. Every slice reaches European consumers with uniform thickness and bright color. This is not just an equipment upgrade, but a reshaping of our competitiveness."
—— A****P Polska, Technical Director Mr. Kowalski
