Tubular Cable Conveying System Drives 70% Throughput Increase at Almond Processor

Unlike pneumatic systems, which can subject fragile products to higher velocities and impact points, the tubular cable design gently pulls product through enclosed tubing. This minimizes breakage, reduces dust generation, and maintains sanitation standards—key considerations in nut processing environments.

Each of the six conveyor runs was custom-engineered with specific horizontal and vertical distances, multiple directional changes, and defined infeed and discharge points. This allowed Almondco to route product efficiently between pasteurization, blanching, storage, and cutting operations without introducing excessive transfer points.

Buffering high-output upstream processes

One of the core challenges addressed by Project Optimise was balancing upstream and downstream capacities. Almondco’s pasteurization and blanching operations can generate product at rates exceeding the capacity of subsequent processing equipment. Without adequate buffering, this mismatch could create bottlenecks or force upstream slowdowns.

To resolve this, Flexicon designed and fabricated two sanitary, custom-engineered storage hoppers, each with a 12,500-kg capacity. Constructed for food-grade operation, the hoppers serve as surge bins, enabling continuous upstream production while downstream processes operate at their optimal speeds.

Low-friction surfaces enable the discs to glide smoothly through the conveying line tubing, ensuring efficient operation while minimizing product hang-up.Almondco/FlexiconTo further protect product quality during transfer, Flexicon incorporated spiral “let-down” chutes beneath conveyor discharge points. Almonds descend in a controlled helical motion, reducing velocity and impact forces as they enter the storage hoppers. This feature mitigates kernel damage during vertical drops—a common failure point in conventional gravity-fed systems.

At the base of each hopper, a vibratory feeder meters product into a downstream tubular cable conveyor, which gently transfers almonds to the cutter line. The result is a controlled, continuous feed that stabilizes line performance and reduces operator intervention.

Controls integration and system synchronization

All six conveyors and associated equipment were integrated into Almondco’s plant-wide control architecture. Flexicon worked closely with a local controls integrator to ensure seamless communication between upstream and downstream assets.

This synchronization allows the conveying system to respond dynamically to changes in process conditions—such as hopper levels or line slowdowns—improving overall equipment effectiveness (OEE) and reducing the risk of unplanned stoppages.

The enclosed design of the tubular cable conveyors also supports food safety objectives by limiting environmental exposure and simplifying cleaning procedures. For processors managing allergen control and sanitation compliance, enclosed mechanical conveying offers both operational and regulatory advantages.

Minimizing downtime through local support

For processors operating in regional areas, access to spare parts and technical support can significantly impact uptime. An additional benefit of working with a domestic manufacturer was Flexicon Australia’s local inventory of replacement components.

With critical spare parts stored within Australia, Almondco reduced the risk of extended downtime associated with international shipping delays. This was a key consideration during a period marked by global supply chain disruptions.

Measurable production gains

Project Optimise was completed in seven months from initial engineering through commissioning. The expanded facility has been fully operational since 2021.

The results have been substantial: Almondco achieved nearly a 70% increase in processing throughput while maintaining its stringent quality standards. The integrated conveying and storage system enabled higher volumes without sacrificing kernel integrity or creating new bottlenecks.

“Flexicon’s design and drafting were spot on,” Haskard says. “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.”

A scalable model for nut and ingredient processors

For food and beverage manufacturers handling fragile particulates—whether nuts, cereals, inclusions, or specialty ingredients—Almondco’s Project Optimise underscores the importance of aligning conveying technology with product characteristics and overall plant capacity.

By combining gentle mechanical conveying, surge storage, integrated controls, and local service support, Almondco created a scalable infrastructure capable of meeting current demand while positioning the company for future growth.

In an increasingly competitive global ingredient market, investments in material handling may not always be the most visible upgrades—but as Almondco’s experience demonstrates, they can be among the most transformative.