New tech helps smooth processing obstacles

Potato processors know the cost of a single stone: halted production, damaged blades, wasted time and unplanned maintenance. New technology from Urschel offers a more robust line of defense.

Designed specifically for the Urschel CC Slicer, the RockRepeller Impeller addresses one of the most frustrating problems in vegetable processing — rock contamination —with a novel, centrifugal solution.

ROCKY PROBLEM

Foreign objects like rocks and stones remain an unavoidable hazard in root crop processing. But they’re not just a nuisance. When they strike knife holders or cutting heads, they can shatter blades, wear down components and bring production screeching to an expensive standstill.

According to Urschel, the RockRepeller Impeller is designed to address this issue head-on. With a patent-pending structure and a system of specialized paddles, the impeller uses centrifugal force to divert rocks away from the cutting zone, minimizing risks.

The RockRepeller Impeller is fitted within the Urschel CC Slicer, a centrifugal slicing machine widely used across the industry. The impeller’s paddles serve a dual purpose: maintaining the product’s forward motion while displacing stones. Paddles work with the specially engineered impeller to channel stones out of the slicing chamber. This proactive redirection helps prevent contact between hard objects and delicate knife assemblies.

The centrifugal force and engineered build of the impeller work together to form physical pathways for stones to separate from the product and become diverted, said Scott Klockow, Urschel director of applications and product development.

“Potatoes, being lighter than stones, are held more tightly within the centrifugal force,” he said. “The impeller stone diverters work simultaneously along with the precision slicing action of each cutting station. Each process works in unison.” This technology is purpose-built for potato processors using the Urschel CC Slicer but has the potential to reach broader markets. Any high-throughput operation working with bulk raw or pretreated potatoes — particularly where incoming loads are sourced from variable or rocky soils — may find the RockRepeller Impeller to be an upgrade, the company said.

TANGIBLE BENEFITS ON THE LINE

Processors who have adopted the RockRepeller report compelling results. One of the most significant outcomes is reduced downtime. With fewer blade-related stoppages, lines can maintain higher throughput and experience fewer interruptions.

Users also noted a marked increase in production flow, suggesting the system not only protects equipment but also promotes better overall efficiency, the company said.

Reports also suggested that processors using the new impeller see up to three times fewer replacements of knife holders and spare parts. This reduction in wear-and-tear extends the lifespan of cutting heads and minimizes repair frequency — translating to lower maintenance costs and improved return on investment.

Return on investment will vary from one processor to another, depending on the volume of potatoes being processed. Large processors that have implemented the new impeller report improved results, Klockow said.

“With ongoing labor shortages around the world, processors rely on rugged machinery, such as the CC equipped with the RockRepeller, to assist their day-to-day operation,” he said.

The RockRepeller is the result of ongoing conversations between Urschel engineers and processors on the factory floor. In a competitive processing environment, eliminating even a few minutes of lost production can deliver major financial returns.

Urschel works directly with food processors to create new equipment and solutions for existing machinery in the field. Potato processors expressed the need for this solution, the company said.

Early testers remarked that the impeller works best with a 32-inch cutting chamber to activate the highest output, Klockow said. Most companies also remarked that they upscaled their lines to the MicroAdjustable 14-station Slicing Head, which has reduced operator-involved error for increased cost savings.

LOOKING AHEAD

As global demand for processed potatoes rises, and with automation gaining traction across food processing, the need for resilient, self-protecting systems will only intensify. Innovations like the RockRepeller Impeller reflect a shift toward smarter hardware that goes beyond performing a task by anticipating problems before they arise.

Potato processors weighing their next capital upgrade may want to consider whether installing this technology could pre-empt costly downtime that chips away at margins. At the same time, plant engineers and production managers may want to evaluate the unit’s ease of use, training needs and whether the addition requires any process reconfiguration, the company said.

For processors dealing with unpredictable raw material loads and tight production schedules, the RockRepeller Impeller could be a development worth slicing into.