Client
Large-Scale Fruit Processing & Export Company
Industry
Fruit Processing & Agricultural Export
Challenge
Manual fruit washing creating production bottlenecks and inconsistent cleaning quality
Background
The client, a food processing and agricultural produce export company, was processing 100 tons of fresh fruits everyday for large-scale domestic and international retail chains. Maintaining pristine fruit quality is non-negotiable; even minor flaws or residual soil can trigger rejections from quality-conscious buyers, resulting in significant financial loss.
Their plants relied on semi-automated washing stations (with manual spraying and mechanical brushing) for 20+ years. While functional, these older systems were labor-intensive and increasingly unable to keep pace with growing demands, especially during peak harvest seasons. Then, there was inconsistent washing that resulted in rejections of some of the batches that they were considering export-ready.
Nexgen Machines was contacted recognizing we have helped food processing plants of similar scale. We implemented an industrial-grade fruit washing system, first in one of their plants. This automated industrial fruit washer is built for high-volume production, consistent results, and water (and energy) efficiency.
The goal was ambitious: accelerate the washing stage, eliminate processing bottlenecks, ensure uniform cleaning quality, and reduce water waste, while maintaining the gentle handling that premium fruit demands.
Challenges
Washing Bottleneck
Manual and semi-automated washing systems couldn’t keep pace with 100+ tons daily volume, increasing risk of bruising and deterioration of fruits during wait times.
Inconsistent Cleaning Quality
With manual spray and brush techniques, some batches were perfectly clean, but others retained soil and residues, leading to export rejections and costly re-washing.
Excessive Water Consumption
Semi-automated systems used excessive water with poor circulation and reuse capability, driving up utility costs and water waste in a water-scarce region.
High Labor Dependency
Manual washing required constant operator supervision and physical labor, increasing hiring cost and creating scheduling challenges during peak business seasons.
Solution: Nexgen Industrial Fruit Washing System
Nexgen deployed a state-of-the-art industrial fruit washing system engineered specifically for high-volume produce processing. The system combines precision-engineered spray patterns, variable-speed conveyor handling, and advanced water circulation technology to deliver consistent, gentle, yet thorough cleaning across all fruit types and volumes.
Key Features:
Faster Washing Operation
Processes up to 150 tons of fruit per day with uniform washing, and seamlessly aligned with harvest volumes and delivery timelines.
Automated and Consistent Cleaning
Automated spray patterns and programmable wash cycles ensure every fruit batch receives identical cleaning treatment.
Multi-directional Spray
Pinpoint accurate spray jets remove dirt and residues from multiple directions at optimal pressure while avoiding bruising of delicate fruits.
Water Recirculation System
Advanced filtration and recirculation technology reuses up to 70% of wash water, while maintaining cleaning efficacy uniformly.
Modular & Scalable Design
Configurable washing stages and variable conveyor speeds accommodate diverse fruit types (from berries to apples), without requiring system modifications.
Food-Grade Materials
Constructed from food-safe, corrosion-resistant stainless steel with easy-access design for rapid cleaning and sanitation.
Implementation
The implementation was structured to ensure minimal disruption during peak harvest season and comprehensive operator proficiency before full production reliance.
Phase 1 – Facility Analysis & System Customization
Nexgen’s technical team conducted an exhaustive analysis of the existing facility, including current wash volume patterns, fruit variety mix, water quality and availability, drainage infrastructure, and space constraints. They evaluated fruit types processed (apples, mangoes, citrus, stone fruits, berries) to tailor spray intensity, conveyor speed, and wash cycle duration.
Phase 2 – Installation and Integration
The washing system was installed in the existing processing line, carefully integrated with upstream sorting and downstream drying/packing stations. We fine-tuned spray patterns, optimized conveyor speeds for each fruit type, and validated wash cycle parameters to achieve export-grade cleanliness without violating fruit integrity.
Phase 3 – Testing
Comprehensive testing was conducted across all fruit varieties using actual production fruit. We also conducted quality testing that included microbial swabs and residue analysis to confirm compliance with export standards.
Phase 4 – Operator Training & Transition to Full Production
A holistic training was provided to production staff on program selection for different fruit types, water filtration maintenance, sanitation protocols, and basic troubleshooting. The system was gradually ramped up to full capacity alongside the existing system during the transition period, allowing operators to build confidence.
Results
50% Faster Washing Cycle Time
Washing time per ton of fruit dropped from 20 minutes to 10 minutes, enabling the facility to process 100+ tons smoothly during peak harvest without backlogs.
99.8% Quality Compliance Rate
Consistent wash cycles achieved export-grade cleanliness on first pass for 99.8% of batches, making costly rejections and re-washing incidence almost negligible.
45% Reduction in Water Consumption
Advanced recirculation technology reduced daily water usage from 50,000 liters to 27,500 liters, which is good for both the environment and balance books.
38% Labor Dependency Reduction
Automation of manual washing tasks required 45%, fewer labor efforts, freeing the team to diversify in other tasks and lifting the burden of periodic temporary hirings.
Client Testimonial
“Fruit washing doesn’t sound like a glamorous operation, but it was absolutely choking our ability to grow our market base. With Nexgen’s system, we’ve not only solved the bottleneck, but we’ve actually improved the consistency of our product quality to a level our export customers explicitly praise.”
– Plant Director, Fruit Processing & Export Company
Conclusion
Nexgen’s industrial fruit washing system eliminated a critical bottleneck for the company, whose reputation was in line. They were not only suffering with unnecessary higher cost due to re-washing and rejection of batches, but were facing the risk of reputation damage. The unforgiving market competition could have plummeted them to the bottom of the preference list; however, one seemingly simple (but crucial) Industrial Fruit Washer saved their business. And, also opened up new market opportunities with the new found confidence they have in the quality of their products.
Note:
For privacy and contractual reasons, the client’s name has not been disclosed and is represented as a “Large-Scale Fruit Processing & Export Company.” All challenges, implementation details, and performance results are based on a real industrial deployment of Nexgen Machines’ Industrial Fruit Washer. While the data reflects actual operational improvements, specific business information and the client’s identity remain confidential.