Vanmark's Natural Flow Gate
Frequently Asked Questions:
Why is it called a Natural Flow gate?
Unlike the “overflow” style gates used up till now, the Natural Flow gate works with the natural movement of product in the peeler bed rather than against it. Thus the name.
What is it so different about this gate and how does it work?
The Natural Flow gate is much different than the gate installed on your peeler now. The standard “overflow” gate acts like a dam to control the depth of product inside the peeler. (The depth of product determines the pressure of product against the rolls.) Once product reaches the level of the dam, it spills over the top. Although this type of gate has been used for years, it not the best solution.
Because it is a barrier, the “dam” halts the forward motion of the mass and counteracts product tumbling action. Rather than a smoothly tumbling mass, temporary dead spots develop at the gate. Some product is briefly trapped while in contact with the rolls and gets overpeeled. Individual product is forced to make its way to the top of the mass, then be in the right position to be pushed over the dam, before it can escape.
The Natural Flow gate overcomes this in two ways. First, the unique shape of the gate enhances tumbling action and eliminates the dead spots. Second, the gate is designed to remove product at the bottom of the mass where most of the forward motion occurs, rather than at the top. Finished product reaching the gate is quickly removed before it can become overpeeled. This combined action reduces peel loss and improves yield.
Which peelers or scrubbers can use the Natural Flow gate?
The new gate is designed to be retrofitted to Series 2700 (single bed) and Series 2800 (dual bed) peelers and will be standard on all new machines in these series
and some models of the new Series 2900 machines, such as the Series 2700 replacement shown here.
How difficult is it to install the Natural Flow gate?
In most cases it will be a simple bolt-on replacement, although in some minor
welding may be required if it is necessary to adjust hinge points. Your
plant maintenance personnel are likely qualified to perform the installation.
I have a “vintage” Model 27 peeler. Can I put the Natural Flow gate on it?
Yes, but installation may not be as simple as with most of the Series 2700
models made after your machine, due to some design changes in the frame and in the discharge area. If you can get
your peeler’s serial number, this will be a big help in evaluating your machine. Upgrading to a newer frame might also be an option. This would allow you to use existing
internal components, but give you some new capabilities along with making installation of the gate easier. The important thing to remember is that you will still recoup your investment in a relatively short time due to efficiency gains.
Can I retrofit my Series 2600 with the Natural Flow gate?
No, unfortunately the Natural Flow gate is not available for Series 2600
machines.
How much better yield can I expect from the new gate?
Although several operations have recently reported reducing their peel
loss by a full percentage point or more, to use an old cliché, “results will vary.”
It will depend on a number of factors relative to your specific operation.
Rather than try to predict how much improvement you might actually achieve, you might ask yourself this question. “What if I only reduced my peel loss by half a
percent? How much extra yield and profit would that mean?"
If, for example, you process 10,000 lbs of potatoes per hour, a 0.5% yield improvement would mean an extra 400 lbs of product from your peeler each 8 hour shift. That might not sound like much, but it translates to 100,000 lbs over the course of a year. [ 400 lbs/shift x 5 shifts/wk x 50 wks/year ] If you are paying 9 cents a pound for raw product that means you just saved your company $9,000.
I use a tumbling unit in my peeler, can I still install a Natural Flow gate?
Yes. However, due to the shape of the new gate, the tumbling unit shaft will have to be shortened and we will need to supply you with new support hardware. But
please read on.
Although you may feel you need the tumbling unit now, you may find that you can eliminate it after installing the new gate.
To date have , tumbling units appear to be necessary only with long slender products like carrots or product that interlock because of its shape.
Potato processing operations which previously used tumbling units found
they no longer needed them after installing the Natural Flow gate due to
improved tumbling action.
Be sure to let us or your representative know if you want to keep the tumbling unit, so we can be sure to include appropriate hardware.
I run big potatoes for French fries. Will the Natural Flow gate work with them?
Excellent question. We have tested the gate in a production setting with relatively large potatoes in a post-steam peel operation and it has performed well. We also know it has worked well with large sweet potatoes. While we are aware that some operations run some very BIG potatoes, especially in the fry industry, there is no reason to believe the gate won’t work well in these operations, too. However, we stand ready work with you if it doesn’t.
Can the Natural Flow gate be used with carrots and other products?
At the time of this writing, arrangements for production testing of the gate with carrots and similar products have not be completed. Our expectation is that the gate will improve yields with carrots, except in the case of long slender product. Operations processing either large, bulky carrots or baby whole carrots should benefit from the new gate. But, as a famous inventor once said, “One test is worth a thousand words.” Watch for further information on this.
How much will it cost me to upgrade my peelers with the Natural Flow gate?
This depends on too many factors to give a proper answer in this forum. Your Vanmark representative or our
equipment specialists
will be pleased to explore this with you. You may also opt to use our convenient
inquiry form.
Are there other benefits to be gained by adding a Natural Flow gate?
Absolutely. For example, the kit for the new gate will include a new discharge hood which will allow better visibility into the peeler and is easier to clean. It also contains a new door, hinges, and latch. Also, the gate is much gentler on product, since the fall over the top of the gate is eliminated.
If you are using an auger discharge, the benefits are even greater. All of the maintenance associated with the auger discharge are eliminated. Also, the risk of grease and/or hydraulic oil over the product zone is eliminated. Of course, since an auger discharge affords no
visibility into the peeler, there is an immediate benefit from being able to
observe process conditions.