Indoor Produce Production

Problem

How to properly process and package leafy greens, while ensuring product integrity, shelf life and adherence to sanitation standards.

While free from external harm and diseases, crops grown indoors lack the durability of their counterparts grown outdoors. The customer had been addressing this concern by manually processing and packing “clamshell” style trays. Higher amounts of throughput and diversified offerings were required to remain competitive in a saturated market space.

Solution

Sharpe worked with the client as they transformed a former warehouse into a full-scale production floor. Serving as both an engineering and design resource, Sharpe developed the system layout, finalized designs, and managed the project through installation. 

Partnered with the client, Sharpe developed a full process flow of the facility, mapped out process piping, collaborated with numerous chemical companies for proper treatment and washing of produce, and enacted environmental controls for proper facility temperature and humidity. Sharpe also coordinated communications with equipment OEM’s, HVAC, and Electrical contractors for the implementation of the components below. 

• Product conveyance– gentle handling for smooth product transport 
• Produce cutting machine– for accurate sizing of the product across multiple different recipes  
• Washing and drying station– designed for handling multiple delicate products 
• Incline Conveyor– scraping capabilities to minimize leafy greens sticking to the belt 
• Multi-head scale– specified for salad and leafy greens to ensure precise weighments per bag, also featured “priority head” software to mix condiment bags with the greens 
• Wash station– custom designed for multi-head components at elevated scale level, resulting in easy cleaning and higher worker safety 
• Vertical Form Fill and Seal– with gas flushing modifications for extended shelf life  

Sharpe oversaw the installation of the complete line, resulting in a stress-free transition into commissioning and full production. 

Results

An automated line, designed specifically for delicate leafy greens and the minimization of mechanical stress on the product.

• Full process and packaging line, capable of handling even the most fragile of indoor-grown crops

• Significant increase in throughput from automated production

• New packaging formats for unique sales opportunities

• Employee re-allocation for more flexible operations

• Higher levels of food safety and sanitation procedures