Maximizing Food Yield: The Power of Automation in Reducing Food Loss

In food processing, its all about efficiency and maintaining profitability, but reducing waste is often overlooked.

In a typical hand-cut salad processing facility, food loss can be a significant issue, it’s not unusual to see processing yields hovering between 80% to 85%.

This, although considered an acceptable yield, means that a substantial amount of edible crop is just wasted - Around 15 - 20% of harvested crop, that doesn’t make it to the consumer — and that's food loss at source.

Typical hand cut de-core processing waste

• Large amounts of ‘good’ harvested product is wasted - negatively affecting Yield.

• Waste transportation cost is high, these costs can be reduced with automation.

The Problem: Food Loss in Manual Processing

Manual post-harvest processes, though the current norm, inherently involve a higher risk of food loss. Human operators, while skilled, generally inadvertently remove more of the edible crop than necessary when coring produce such as lettuce. In these traditional settings, processors are left with yields that often fall short of their potential, making it difficult in some cases, to maximize profitability.

For instance, in a hand-cut facility processing iceberg lettuce, a large portion of the edible crop is lost in the trimming process of removing the core.

The result is not just inefficiency, but a missed opportunity to ensure that more food reaches the consumer - a missed opportunity to reduce waste. Which is the real challenge for companies looking to streamline operations and meet sustainability goals.

With yields typically in the range of 80% to 85%, there is no doubt that food loss is occurring — but it doesn't have to be this way.

Robotically De- cored Iceberg

The Solution: Automation for Increased Yield

Robotics is changing the outlook for food processors, especially in high-volume precision tasks like fresh-cut salad production. Automation significantly improves processor yield by cutting food loss at source, ensuring that a higher percentage of the crop makes it to the consumer table.

This advanced technology can de-core 55 heads of iceberg lettuce per minute with a single robot, and achieve a staggering improvement in yields.

The Extractacore robotic systems consistently achieve yield rates between 90% and 97%, leaving no edible produce around the core after extraction.

Typical automated de-core processing waste

• No ‘good’ harvested product is wasted - positively affecting Yield.

• Waste transportation cost is low, these costs have been reduced with automation.

By reducing food loss at the source, robotic automation ensures that almost all of the lettuce - apart from the core! - is preserved for packaging and distribution.

This immediately boosts profitability in two ways - firstly by increasing yield, and secondly by cutting costs in waste transportation and disposal - effortlessly aligning with growing industry demands for sustainability and waste reduction.

The Bottom Line: Automation Delivers

When it comes to reducing food loss and improving operational efficiency, the difference between the traditional hand-cut method and automated processing is striking.

Processors face a constant battle with waste and low yields, automation brings a clear consistent path to higher yields, minimal waste, and a stronger bottom line - automation is the clear winner.

Adoption of robotic systems offers opportunity to both the processor, and the consumer - significant food loss reduction, enhanced operational efficiency, and higher-quality, competitively priced product for consumers.

Rapid Robotic Processing

A fresher, and larger percentage of harvested crop reaches the consumer.

As we continue to transform the food processing industry, those who embrace technology will be equipped to meet market demands, improve profitability, and reduce their environmental footprint.

Automation isn’t just an efficiency upgrade — and rapid robotic de-coring is a strategic investment.