Client
Fruit Processing Unit
Industry
Food Processing & Packaging
Challenge
A fruit processing unit specializing in custard apple based products relied heavily on manual methods for pulp extraction. The process required skilled labour, involved multiple handling steps, and led to high wastage and inconsistent pulp quality.
Background
A fruit processing unit specializing in custard apple based products relied heavily on manual methods for pulp extraction. The process required skilled labour, involved multiple handling steps, and led to high wastage and inconsistent pulp quality.
As seasonal demand increased, the unit faced rising labour costs and struggled to scale production without compromising quality. To improve throughput and reduce dependency on manual labour, the company sought an automated pulping solution.
They partnered with Nexgen Hygiene Systems to implement a Custard Apple Pulper designed for efficient, high-yield pulp extraction with minimal manual intervention.
Challenges
High Labour Dependency
Manual peeling and pulping required a large workforce and continuous supervision.
Low Processing Speed
Batch-wise manual operations severely limited daily production capacity.
Inconsistent Pulp Quality
Variations in manual handling affected texture and yield, causing inconsistencies.
Increased Processing Costs
Rising labour expenses and increased processing time reduced overall profitability.
Solution: Custard Apple Pulper
Nexgen Hygiene Systems supplied a Custard Apple Pulper engineered to automate pulp extraction while maintaining superior product quality and minimizing fruit wastage.
Key Features:
Automated Pulp Extraction
Efficiently separates pulp from seeds and skin with minimal manual input, streamlining the entire process.
High Throughput Design
Processes large volumes consistently and reliably, supporting scale-up requirements during peak demand periods.
Food-Grade Construction
Built with hygienic, corrosion-resistant materials specifically suited for fruit processing applications.
Low Wastage Mechanism
Optimized extraction technology improves pulp recovery rates and significantly reduces product losses.
Easy Cleaning & Maintenance
Designed for quick dismantling and sanitation between batches, ensuring hygiene compliance and minimal downtime.
Implementation
Phase 1 – Process Evaluation
Nexgen’s team conducted a thorough assessment of current processing volumes, labour usage patterns, and yield losses to establish baseline metrics.
Phase 2 – Installation & Trials
The pulper was installed and rigorously tested with actual fruit loads to optimize machine settings for maximum efficiency and quality.
Phase 3 – Operator Training
Staff received comprehensive training on machine operation, cleaning protocols, and basic maintenance procedures to ensure smooth adoption and long-term success.
Results
Reduced Labour Costs
Automation significantly lowered dependence on manual labour, reducing staffing requirements and associated costs.
Faster Processing Time
Pulp extraction time was dramatically reduced, enabling substantially higher daily output and improved capacity utilization.
Consistent Pulp Quality
Uniform, mechanized extraction improved product consistency and enhanced downstream processing efficiency.
Improved Profitability
Lower operational costs combined with higher throughput enhanced overall margins and return on investment.
Client Testimonial
“The Custard Apple Pulper transformed our processing line. We’ve reduced labour requirements and can now process higher volumes without compromising quality.”
– Operations Manager, Fruit Processing Unit
Conclusion
With Nexgen’s Custard Apple Pulper, the fruit processing unit successfully streamlined its operations, reduced costs, and improved processing efficiency. The automated solution enabled scalable growth while maintaining consistent product quality, all while addressing labour challenges and meeting increasing seasonal demand.
Looking to automate fruit pulp processing?
Reach out to Nexgen Hygiene Systems to explore how our pulping solutions can improve efficiency, reduce costs, and boost profitability for your operations.