“It’s efficient, has no electricity requirements, and provides 99.999% cleanliness of the air. It’s so easy, we don’t need to think about it.” – Adrian Bright, Farm Owner, Montford Farm
Ready to Stop Equipment Failure and Save Thousands?
Project Background:
“If the fingers on the optical grader seize up, we’ll be back to hand-picking. We need to get going and keep going.” – Adrian Bright, Farm Owner, Montford Farm
Montford Farm had recently acquired an optical grader to detect and remove discoloured or misshapen potatoes from the production line. The machine is essential for maintaining high product quality and meeting buyer standards. Optical sorting machines are extremely sensitive to compressed air contamination. Contaminants like liquid water, oil emulsion fluids and solid particulates can cause the finger ejector to operate inconsistently or fail.
The finger ejector physically removes rejected items like rocks, clumps of mud, or defective potatoes from the line. If this component fails because of compressed air contamination, the pneumatic cylinder in the ejector unit will need replacing, not including labour and downtime. Without a functioning ejector, unwanted materials continue through the production lines, risking customer complaints, rejected loads, and reduced market value.
Compressed air contamination can also deposit on critical components of optical graders, such as lenses and sensors, reducing image clarity and sorting accuracy. The machine will then misclassify the farm’s potatoes, increasing rejection rates and causing product quality issues.
For Montford Farm, unplanned downtime means the team will hand-sort potatoes, creating labour shortages and drastically increasing labour costs.
Summary:
Expel successfully eliminated the risk of compressed air contamination on the optical grader. It is the only solution on the global market that could provide Montford Farm with no ongoing energy, component, or maintenance costs.
The farm needed a permanent compressed air preparation method to ensure sustained efficiency and avoid costly interruptions or damage. After analysing all available solutions, Expel offered an unrivalled specification.
Conventional solutions, particularly refrigerant dryers, are poorly suited for environments with heavy mud, dirt, and solids. These conditions can quickly clog the system, reduce efficiency, and lead to frequent maintenance and failure. Therefore, the farm’s optical sorter could be left unprotected against contamination.
Expel compressed air filters are the ultimate, reliable, low-maintenance solution. Unlike traditional filters and dryers, Expel removes all three primary sources of contamination without consumables, electricity, or maintenance. Expel’s performance remains consistent, even after years of use. Its advanced filtration technology uses physics to separate the contaminants from compressed air, and a gravitational pull discharges them from the filter. With no moving parts to clog or fail, Montford Farm can fit and forget about Expel with complete peace of mind that Expel is safeguarding the optical grader.
The Results:
Optimised Efficiency: By delivering consistently clean air, Expel stops the finger ejector from sticking, misfiring, or wearing out prematurely, causing errors and downtime.
Reduced Operational Costs: Conventional compressed air preparation methods, like dryers and traditional filters, have hidden operational costs. Expel is the only solution on the global market that could provide Montford Farm with no ongoing energy, component, or maintenance costs. With fewer breakdowns, less maintenance, and a 10-year guarantee, Montford Farm will save time and money year after year.
Eliminated Causes of Downtime: Contaminated air is a major cause of unexpected breakdowns in optical sorters. Expel removes this risk, keeping mechanical reject systems operating reliably and reducing interruptions to grading operations.
Superior Equipment Protection: Expel protects critical components like the finger ejector, valves, and sensors by removing three sources of contamination. Therefore, Expel stops corrosion and wear, rapidly resulting in component failure.
Our team is ready to answer your questions.
David specialises in improving business efficiency. By building strong industry relationships, David ensures Expel’s revolutionary technology delivers real value to businesses.
With vast pneumatics knowledge, Johan specialises in on-site assessments to identify strategic installation points to maximise performance and eradicate contamination.
Lauren is a key point of contact for customers. She handles general inquiries and provides exceptional after-sales support, ensuring a smooth customer experience.