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Complete Vegetable Processing Line at a Malaysian Frozen Food Factory: Turnkey Installation — learn how Yuerui Machinery supports your production with reliable equipment and engineering.
This project documents how a Yuerui Machinery customer deployed a complete turnkey vegetable processing line to transform their frozen food production operation. The installation details, throughput figures, and ROI data below are shared with the customer’s written consent. Company names are withheld per mutual NDA terms.
Project Background
The customer – a major frozen food manufacturer serving Southeast Asian retail chains – was operating a semi-manual vegetable preparation process that had become the bottleneck in their production. With demand for frozen vegetable mixes, stir-fry packs, and ready-to-cook meal kits growing 25% year-over-year, their manual washing, cutting, and blanching operation could not scale. Product inconsistency, labor shortages, and food safety audit pressure drove the decision to invest in a fully automated complete vegetable processing line.
Needs Assessment and Line Design
Yuerui’s engineering team spent three weeks on-site conducting a comprehensive production audit. The assessment covered the customer’s full product range (12 frozen vegetable SKUs), shift patterns, existing factory layout, utility capacity, and cold chain logistics. Based on the findings, we designed a turnkey line integrating six processing stages:
- Stage 1: Vibrating feed conveyor with soil pre-removal for root vegetables
- Stage 2: Multi-stage brush and bubble washing with water recycling
- Stage 3: Abrasive peeling station for potatoes, carrots, and onions
- Stage 4: Multi-function cutting station with PLC recipe management for 8 cut styles
- Stage 5: Continuous belt blancher with automatic temperature control
- Stage 6: Cooling flume and discharge to existing IQF freezer
The complete line was designed for 2,500 kg per hour throughput with changeover between vegetable types in under 15 minutes.
Installation and Commissioning
Installation was executed in two phases over eight weeks. Phase one installed the washing, peeling, and cutting stages while the customer’s existing manual line continued operating. Phase two integrated the blanching and cooling stages and connected the line to the existing IQF freezer. Yuerui technicians handled all mechanical setup, electrical integration, PLC programming, and water system connection. The commissioning period ran for three weeks with parallel production – the new line operated alongside the manual line while quality was validated. Formal handover took place after 5,000 sample units passed the customer’s quality team inspection.
Production Results After 90 Days
The customer collected comprehensive production data over the first 90 days of full operation:
- Line throughput maintained at 2,400-2,600 kg per hour across all 12 SKUs
- Product yield reached 98.5% – a 6% improvement over the manual line’s 92.5%
- Direct labor on the vegetable preparation line reduced from 32 operators to 8 per shift
- Cut consistency variance reduced to plus or minus 1mm across all cut styles
- Changeover time between SKUs averaged 12 minutes (target was 15)
- Water consumption reduced by 55% per kg of product through the recycling system
- Estimated payback period of 20 months based on labor savings, yield improvement, and capacity increase
Food Safety and Quality Outcomes
The integrated wash line’s multi-stage approach – brush washing, air bubble cleaning, and spray rinsing – consistently achieved microbial reduction levels that exceeded the customer’s previous manual process by 2 log CFU/g. The continuous belt blancher’s precise temperature control (plus or minus 1 degree Celsius) eliminated the under-blanching and over-blanching issues that had caused periodic product recalls on the manual line. The PLC recipe management system provided full traceability for each production batch, simplifying HACCP audit preparation and customer compliance documentation.
Operator Feedback and Training
The customer’s production manager noted that the transition from manual to automated processing required significant operator retraining. Yuerui provided a four-week operator training program covering line operation, recipe management, sanitation procedures, and basic maintenance. The PLC touchscreen interface with visual recipe icons was specifically praised for reducing the learning curve. Retrained operators reported higher job satisfaction, and the plant retained 95% of its workforce through the transition.
Expansion and Next Steps
Following the success of this installation, the customer has signed a framework agreement with Yuerui to deploy a second complete line at their facility in Penang, Malaysia. The second line will add automatic weighing, MAP packaging, and case-ready formatting to create a fully integrated frozen vegetable production cell. The customer also plans to add RFID product tracking for full farm-to-freezer traceability in phase three.
Request a Similar Assessment for Your Factory
Every Yuerui project begins with a no-obligation process audit. Our engineers will review your product range, throughput targets, factory layout, and existing utilities, then propose a turnkey solution matched to your operation. Contact our team to schedule your assessment, or explore our full vegetable processing equipment catalog for individual machine options.
