Since this fall, all processing points, drop points, and transfer points in the Verhage partnership's shed have been encased in transparent plastic tents and equipped with dust extraction. "The air in our processing area is clear, so we've made a huge difference," says Marien Verhage about the results. "There are still a few minor issues for which we've devised alternative or additional solutions in practice together with Jongejans. These will be implemented soon. Achieving 100% dust-free operation isn't feasible in our current situation. We're quite busy transporting crates, so we always keep soil and dust on the floor. With the electric forklift and regular vacuuming, we're also limiting this source."‘
Work comfort is important
Potato processing generates a lot of dust. This can be detrimental to job satisfaction and health. "Everything you can do to improve your work comfort helps your company's image. A dust-free work environment is a key component," Verhage explains, explaining his decision to work dust-free. The grower explains that dust-free working is not only good for the health of those working in the shed, but also for the product. "Dust and germs are less likely to be absorbed into the processing, and finished product stays cleaner for delivery. Machines can also stay cleaner, resulting in less wear and tear," he says. Annually, Verhage processes 3,500 to 4,000 tons of seed potatoes from its own fields and those of fellow growers. This provides a valuable source of employment for freelancers during the winter months, when it's typically a quieter period. On average, the partnership employs three to four people in the sorting process. One or two people work on the inspection conveyor belt, one forklift driver for sorting and the infeed and outfeed inspection line, and one person for bagging and other logistics. They now work in a much cleaner space than before and are very satisfied.
All in one go
Within the partnership, there had been discussion for some time about tackling dust at the source. It was clear that, in addition to packaging the machines and tipper(s), active extraction was necessary. Initially, Marien Verhage considered phasing out the packaging and extraction. He decided against it. "Ultimately, phasing is more expensive, because you'll likely be purchasing several smaller units. And even then, you still won't be rid of the dusty environment. With the machines we have now, we want to last for several years. That's why we've decided to tackle everything at once. Besides, we've become accustomed to the investment amount by now."“
Proven technology
In his search for solutions for a dust-free work environment, Verhage had already contacted Jongejans Luchttechniek from Den Helder. He decided to work with this company. "An established name, with extensive experience and proven technology," the arable farmer explains his choice. "They had been here regularly in previous years, when we were still discussing a phased approach, and they provided us with extensive advice on the points to be addressed. Ultimately, we combined the plans from previous years into a single, smarter, and more comprehensive plan. The entire processing process was mapped out, measured, and the necessary technology was determined. In seed potato processing, you often change varieties or sizes, and that means you have to be flexible with the extraction points for cleaning and inspection."“
Warm air is retained
Jongejans installed the Agra PGF 500 at Verhage, a powerful 18.5-kilowatt dust extraction system with a whisper-quiet high-efficiency fan and filters that are automatically cleaned with compressed air. The system stores the dust in two rolling containers. The system inhales polluted air and then exhales clean air after filtration. Because the PGF 500 is installed indoors at Verhage, 100% of the warm air is retained. This means that purifying the air doesn't compromise the indoor climate.
Installed in two weeks
A permanent team of installers worked for almost two weeks on the system installation. Because everything went smoothly, the agreed-upon date of November 1st was met. Meanwhile, seed potato processing had already begun. "Thanks to good communication and clear agreements, this didn't cause any problems," says Verhage.
Partnership Verhage in Emmeloord
The Verhage partnership consists of Marien Verhage and both his parents. The company, located in Emmeloord since 1951, specializes in seed potato cultivation. The partnership cultivates approximately seventy hectares of seed potatoes. Of these, a quarter are destined for early export, fifty percent are grown for Europe and transplanted by colleagues, fifteen percent are starch varieties, and ten percent are French fry varieties. In addition to cultivation, the company also handles processing in-house. Several hectares are also sorted and bagged for colleagues. The seed potatoes are stored in crates.
Step by step through the seed potato processing process
The key aspects of the dust extraction solution at Verhage, according to Rémon Koopman and Jesse Vonk of Jongejans Luchttechniek.
PGF 500 setup
The air in the processing area is extracted by the PGF 500. This system is located indoors and blows purified air back into the processing area, preventing heat loss. Verhage has three processing lines, but it's rare to use all three simultaneously. The PGF can extract air from two lines simultaneously. Continuously extracting three lines would require a significant investment. Through smart software and PLC control, along with pneumatic valves, Verhage can select which two lines require extraction. A frequency controller ensures that the fan speed is adjusted to the required capacity. The Agra PGF filter is specifically designed for potato dust. Around a hundred systems are already in operation, and this proven technology is used annually by dozens of processors.
Sorting line
At the tipper on the sorting line, dust only needs to be extracted for a short period at a time. A sensor therefore pneumatically opens or closes the extraction vent when needed. Sealed dust tents are placed over the hedgehog belt and the outlet, the sorting unit, and each trap. This creates a negative pressure to maximize dust extraction.
Reading line
Here too, a sensor ensures that the extraction at the tipper can be pneumatically opened or closed. A closed dust tent is placed over each trap or large dust source.
Packaging line
The extraction system at the tipper is automatically opened and closed pneumatically. The VHM crate filler is fitted with a sealed dust tent, preventing dust from escaping when filling crates or big bags. The weigher also has a sealed dust tent. At this stage, the potatoes have already passed through three lines and are quite dry. At the weigher, they make a rapid movement, creating a lot of dust. When bagging the potatoes, slotted tubes extract air. The lint trap filters the jute from the dust, preserving the filters.
