Key Technology Introduces onCore™ Fresh-Cut Core Removal System

January 13, 2010 – Key Technology introduces onCore™, a new integrated system that revolutionizes the processing of iceberg and romaine lettuces in bagged salads.  The system, which combines a vibratory density separation shaker with a camera/laser sorter, eliminates manual coring to increase yields and improve product quality while reducing labor costs.

In addition to eliminating manual coring, onCore simultaneously removes foreign material and product defects from the production line, further improving product quality and food safety.

Currently in use at leading fresh-cut produce processing companies in the U.S., Canada, and the U.K., onCore is driving a paradigm shift in how iceberg and romaine are processed.  Traditionally, these lettuces are manually cored in the field or in the plant.  Manual coring causes excess product to be cut away to assure the core is fully removed and the highly nutritional outer leaves are typically discarded as well.  Significant yield is lost, the nutritional value of the product suffers, and labor costs are high.

With onCore, the whole, uncored heads of lettuce are brought into the plant and cut using the same automated cutting technology that is traditionally used to cut cored heads of lettuce.  After cutting, onCore’s two-step process removes the pieces of core as well as foreign material and defects from the product stream.

First, onCore’s three-deck Iso-Flo® Density Separation Shaker uses gravity and directional airflow to remove 85 to 90 percent of the core and spread product to present it to the downstream sorter.  The effectiveness of this process reduces the volume of core being fed to the sorter, which helps the sorter focus on removing the smallest pieces of core along with foreign material and leaf defects.

The second part of the onCore process is the sorter.  onCore can be designed using Key’s Optyx® or Manta® sorter, depending on the necessary capacity of the line.  The sorter is equipped with a combination of Key’s Raptor laser technology and tri-chromatic color cameras.  The laser detects differences in the structural properties of objects to remove pieces of core and foreign material.  The cameras determine each object’s size, shape, and color to identify and remove defects. 

Based on Key’s extensive experience customizing sorters for a wide range of products, the ideal wavelengths – from infrared to ultraviolet – are identified for each application to accentuate the differentiation of good product from core, foreign material, and defects.  Key then configures the sorter with the optimal combination of lights, lasers, and cameras to produce and capture the exact wavelengths that maximize the sorter’s performance for the specific application.

Using Key’s small-volume Optyx 3000 series sorter, onCore processes up to 5000 lb (2268 kg) of iceberg or 4300 lb (1950 kg) of romaine per hour.  For high volume lines, Key can design onCore using its Manta 2000 series sorter, which processes up to 16,000 lb (7258 kg) of iceberg or 14,500 lb (6577 kg) of romaine per hour.  For mid-volume lines, Key’s Optyx 6000 series sorter or Manta 1600 series sorter are ideal.   

By eliminating manual coring and keeping the dark outer leaves, less good product is removed, which improves yields.  By eliminating manual coring, the potential for laborers to inadvertently contaminate product is reduced and product degradation is slowed, thereby enhancing the quality of the product and increasing its shelf life.  For romaine, a more uniform cut is achieved when whole heads are cut, thereby improving the consistency of the product.  Product quality and food safety are maximized because the sorter removes foreign material and defects along with the core.

Based on yield increases and labor cost reductions alone, onCore achieves a payback in four to 16 months.  Improvements in product quality and food safety further improve the equation.

The patented, icon-based graphical user interface (GUI) is easy to learn and use, reducing operator training and simplifying optimum operation.  Product settings can be stored and retrieved for fast product changeover.  The GUI can reside locally on the sorter and can be accessed remotely via network or Internet, enhancing the flexibility in the operating environment and easing access for remote factory troubleshooting and application assistance.  Sophisticated real-time and on-demand diagnostics help minimize and avoid costly downtime, and detect conditions that could compromise inspection.

About Key Technology, Inc.
Key Technology, an ISO-9001 certified company, is a leading designer and manufacturer of process automation systems, integrated electro-optical inspection and sorting systems, and processing systems. Key® systems help processors to improve quality, increase yield, and reduce cost. With worldwide sales representation, the company maintains demonstration and testing facilities at its headquarters and manufacturing divisions in Walla Walla, Washington, USA, and at Key Technology BV in Beusichem, the Netherlands.  The company's common stock trades on The NASDAQ Global Market under the symbol: KTEC.