How are walnuts processed? How walnuts are processed Walnut processing and drying line

Today, walnut processing is a very good idea for small businesses.

In this article, using the example of Ukraine, we will consider such a type of small business as walnut processing. So there are climatic conditions that not in every country walnuts can grow and ripen. In Ukraine, 120-130 yew grows annually. tons of walnut and in this indicator only the USA and China can compete with Ukraine 460 yew. t and 700 yew. t, respectively. However, in China, almost the entire walnut crop goes to the domestic market, the same situation is in the United States, so Ukraine proudly ranks first in the export of these products (more than 80% of products are exported).

In any kind of business, including small business, the most important thing is profitability. Therefore, before starting this small business, you need to carefully calculate everything and draw up a business plan. I must say right away that not everyone succeeds in processing walnuts. The profitability of walnut processing is about 50%. In this business, a very important role is played by who you will sell the finished product to. If you focus on the domestic market, then the profit will not be so great, but if you try to reach large buyers abroad, then your profit will be much higher. But reaching out to overseas wholesalers is not easy, so many manufacturers donate processed walnuts to domestic wholesalers.

Types of shell cleaning.

When processing walnuts, there are several ways to clean them from the shell:

manual cleaning;
vacuum method;
mechanical method;
soaking with roasting;
cleaning with a sizing - crushing apparatus.

Now let's look at each method in more detail.

Manual cleaning walnuts from the shell is the most ancient method of cleaning, which has survived to our time. The profitability of this cleaning method is very low. People who are engaged in nut shelling receive a pittance at such enterprises, there is a very large turnover of personnel and often people who have nowhere else to go, pensioners and disabled people work. How does this cleaning method work? There are large tables at which workers are sitting. There are large heaps of walnuts in the middle of the tables. Beside each worker there are containers for shells, quarters, halves and chops. This type of cleaning has remained in China, we practically do not have such workshops.

Vacuum method peeling walnuts is already a more advanced method compared to manual processing. The technology is as follows: walnuts are loaded into a container for compressed air, after which air is pumped into the container by a compressor and after a while it is abruptly discharged. From a sharp drop in pressure, the walnut shell does not withstand and bursts.

Mechanical method of peeling nuts... The walnut peeling technology is as follows: the walnut is poured into the hopper, then the walnut is fed to the press, which breaks the shell with the help of mechanical pressure on the walnut. The pressure on the press is regulated, depending on the quality of the nut and the thickness of the shell. A significant disadvantage of this method is that all nuts are different and the pressure for their peeling is different, so a lot of rejection is obtained which the press simply crushed. You also need to constantly regulate the pressure, and this greatly slows down the process of peeling the walnut.

Soaking with roasted walnuts... The technology is as follows: the nut is poured into a container with water and soaked for a while, then it is placed in an oven with a temperature of 600 to 900 degrees Celsius for a few seconds. Excessive pressure is created inside the nut and the shell bursts.

Cleaning with a sizing - crushing apparatus, this is the most common type of walnut shelling. The technology is as follows: the nut is sieved into fractions with the help of a calibration sieve, and then it is fed through a conveyor belt to the crushing apparatus. In the crushing department there are several compartments for different fractions or one, the size of which is regulated depending on the fraction. The walnut in the crushing apparatus is cracked and fed to the winnower, which separates the shell from the kernel. Then the nut goes to a calibration sieve, which separates the various fractions of the kernel.

It is worth noting that whichever cleaning method you choose, you should not forget that whatever equipment you have, you still have to do some manual work. Alas, there is no way without it.

Walnut processing: equipment.

Equipment for peeling and processing walnuts is quite expensive, so many novice businessmen make it with their own hands. If finances allow you, then it is better to buy ready-made equipment. This will firstly increase the productivity of your small business, and secondly, you will not have to rack your brains over the development of new equipment. The approximate cost of a line for peeling walnuts is from 200 to 900 yew. dollars. This is certainly not enough.

Walnut processing: purchase of raw materials.

The purchase of raw materials is the most important aspect this small business. During the year, the price of round walnut varies greatly. The lowest cost per season, and then the price rise right up to the next season. Therefore, large walnut processors purchase large quantities per season, and then dry them and store them in a warehouse. But in order to purchase such a large batch, which would be enough for a whole year, large investments and large storage facilities are needed. Also, during storage, it is necessary to maintain the correct maintenance regime so that the nut does not get wet and dry. The purchase of raw materials can be carried out in bulk from large owners of walnut orchards, as well as from the population. Buying from orchards is good that the nut is of the same variety, and consequently the shell is the same and the same size, and this will greatly facilitate the subsequent calibration of the round nut and reduce losses during shelling. When buying a round nut from the population, you will save a lot, but the nut that you buy will be collected under different trees and will have to be calibrated more carefully. Also, when buying a nut from the population, one must not forget that there are varieties of nuts in which the shell is thick and it peels off very badly. So when buying raw materials, you need to look both ways and choose products very carefully so as not to be left without a profit.

GOST standards according to which nuts are divided.

After splitting, according to GOST standards, the nuts are divided into the following categories:

“Extra” class contains halves and quarters, but their content should not exceed 10%;
The first grade allows the content of 15% of the total mass of 1/8 nuts.
Halves, this category includes halves of a nut, while their content should be at least 80% of the total mass. The remaining 20% are quarters and the core is three quarters of the halves.
Quarters.

The kernels are sorted on a sieve sieve.

Also, the price and quality of the sold walnut kernel is affected by its moisture content, it should be no more than 10%.

Walnut Processing: Small Business Expansion.

If you have decided to seriously engage in walnut processing, then you should think about creating your own garden. This will greatly reduce the cost of raw materials and make your enterprise not dependent on anyone. Also a big plus is that you can plant nuts at your place. good quality, which will greatly facilitate the processing and calibration process for you. For a garden, you just need to rent 50 hectares of land from the state for 49 years. Of course, you will not have to invest badly financially, but the garden will fully pay for itself in 3 years. Also, you can not only sell shelled nuts, but also you can sell round nuts.

The article is in the section: Business ideas with medium investment.

Walnut processing is developing today, gaining momentum and attracting more and more people. Some, who once tried their hand at the nut business, do not stop, but, on the contrary, increase the scale of nut processing. And there are people for whom this business did not go, the invested funds did not pay off and the nut business came to naught. Why walnut processing can curdle, and what are the main reasons for a failed walnut business?

The main reasons why the nut business "didn't go"?

Poor quality raw materials. The most important product that you will deal with is a walnut, and the most important task at the first stage is the purchase of high-quality walnuts. Further processing, processing time and, of course, the most important thing - the integrity of the kernel at the exit and, as a result, its value on the market, will depend on how good the walnut is purchased.

Walnut without sizing. Many walnut growers skip such an important process as nut sizing - sorting the nut by size for further high-quality splitting. We all know that in Ukraine there are few high-quality nuts and all the nuts we buy are nuts from different trees, different varieties, sizes and qualities. And when the splitting process begins, such a nut splits unevenly, with a large percentage of undershooting or, even worse, cracking, the integrity of the kernel decreases.

*Important! Working with an uncalibrated nut, you lose from 20 to 40% of the whole kernel (depending on the quality of the nut and other factors)!

Incorrectly selected equipment. Before starting processing, namely, splitting walnuts, you need to estimate how much walnut per day / week / month you plan to split, how many workers will work with the walnut and even then plan what kind of equipment for processing walnut you need to buy. Often people are chasing fast splitting, high performance of equipment, but not everyone understands that for different volumes of nuts, quick splitting can be reflected in different ways.
Recruitment of staff and outsourcers. When the main stages of processing have been passed - sizing and splitting of nuts, the next, important, sorting, cleaning and bulkhead of the walnut comes in turn. Hiring unskilled people or people “from the street”, due to inexperience, you risk getting, as a result, not a qualitatively sorted out whole core, but a split mix (quarters, halves, eighths of the core).

Unfitted walnut processing facility. Highly important point in the processing of nuts, this is a room where not only equipment for calibration, nut splitting will be located, but also a place for drying nuts, convenient workplaces for bulk pickers, food containers and boxes for kernels, a place for storing nuts, etc.
Lack of sales contacts. The last, but not least, process is the sale of the walnut after processing. Often, not having information about where the walnut can be sold, walnut producers send batches of walnuts to the market, where resellers buy walnuts at an inexpensive price and then sell them at twice the price.

How to avoid failure?

Buy only high quality walnut of this season, pleasant to look at, no cracks, uniform color and smooth shell. Trust trusted sellers, be sure to test the nuts before buying, selectively chop a couple or three nuts from different parts of the bag, so you will protect yourself from buying a "pig in a poke". Read more walnut purchasing tips here - Walnut Purchasing Tips.
Calibrate the nut! This can be manual sorting of nuts by size, if there are not many nuts, or mechanical calibration of the nuts with equipment. In any case, you will keep the core intact during a split, avoid underbreaks and, accordingly, additional manual bulkhead. Buy calibrator for walnut - Calibrator for walnut.
Before starting work, estimate the volume of your production. If you are a beginner walnut grower, you have a small volume of nuts, then you should not pursue high productivity and fast splitting. Start with small mechanical equipment, so master the splitting skills and keep the core intact. Working on electrical equipment with a small amount of nut will not work well; on the contrary, every flaw in the nut will be visible. You can take risks and buy large equipment with small volumes when you have a perfect, calibrated nut.

For large, industrial processing, opt for more professional equipment, where the quality and processing speed are at a high level. Such nutcrackers can work without calibration, which will significantly reduce the cost of calibration equipment and speed up the splitting process.

For the bulkhead, hire qualified people who were engaged in the bulkhead of the nut, they know all the nuances of nut processing. Equip staff with additional tools that will speed up the work of cleaning and bulkhead walnut, protect the bulkhead from injury and cuts. If your business is just starting to develop, you can attract relatives to work, so you will save on staff salaries and be sure of the quality and honesty of work.
To optimize the workflow, it is necessary to equip the workroom with everything necessary for the complete and efficient processing of walnuts. The room should have an equipment area where nutcrackers, calibrators, vibration tables, etc. will be installed. Further, it is necessary to equip an area for working personnel - bulkers, bulkhead tables, lighting, additional tools for cleaning nuts, containers for kernels and recyclable materials. The better the workflow and the space are, the more efficient the work and the end result will be!
For the sale of a walnut, namely a kernel, it is necessary to establish sales contacts and find sellers who would buy it dearly. The easiest way to find such people is on the Internet, in social networks or on message boards, where each has a higher and higher price. There you can also find import partners who are ready to buy nuts from other countries, this option is much more profitable and profitable. Do not forget about the waste - the shell and the partition, from which you can also sell and make money!

We see that the nut business has its own nuances, mistakes and pitfalls that can pull back. However, by following the tips and tricks, they can be avoided! Develop your nut business with the Orekhovod company!

This business project is the construction of a walnut processing plant on the territory of Moldova and the purchase of 100 hectares of land for planting an intensive walnut, which generates income for 4 years. The gross harvest of walnuts per hectare is 3 tons. The walnut processing plant, during the entire period of the garden's growth, will work intensively, that is, the purchase of peeled or not peeled walnuts from the population at a cost below market prices will be dried. All assembled products will be sold in Europe and the CIS countries, where the cost of these products is much higher, and the quality is at the level of foreign analogues. After the walnut garden in both 100 hectares bears fruit, the volume of production will be 300 tons of walnut and the cost of this product will be 5,000,000 euros. Business plan: Walnut orchard (walnut)

DESCRIPTION OF THE BUSINESS

1. Planting and operation of a walnut orchard with an area of 100 hectares

COMPETITIVENESS

CONCLUSION - According to these calculations, the payback period of the walnut garden is within the critical maximum of 5 years! - The project participants form and strengthen the walnut business. - European partners provide their region Business plan: Walnut orchard (walnut)

DESCRIPTION OF THE BUSINESS

A business plan is being considered for a comprehensive program of a closed cycle of the nut business:

1. Planting and operation of a walnut orchard with an area of 100 hectares,

2. Processing of walnuts (peeling, sizing, pre-sale preparation).

3. Making nut butter and crushing walnut shells for further use.

COMPETITIVENESS

The business will be successful due to the following:

1. A potential client has an urgent need for a product;

2. Waste-free production of business (wood, leaves, branches, roots are raw materials for light, food, chemical and pharmaceutical industries);

3. Long-term profit (100-120 years);

4. Long shelf life of the product, no special storage conditions and simple transportation conditions.

PRODUCT - Calibrated and packaged walnuts for sale on the European market. - Quality calibrated walnut kernels in vacuum packaging for European sales. - Walnut oil for food, perfumery and pharmaceutical industries. MARKET AND COMPETITION Annual product shortage in Europe is 100,000 tons. The taste qualities of our product (Ukrainian walnut) are superior to those existing, except for the USA (California).

Business is exposed to the following risk factors:

1. Climatic conditions (global climate change);

2. Human factor(vandalism, theft);

3. Natural pests: Walnut moth (Gracillaria rosciopenella), walnut moth (Сydia pomonella)

1. CALCULATION OF INCOME FOR LANDING AND OPERATION OF A WALNUT GARDEN

At the moment, the potential client is in dire need of the product and offers 1.2 euros / kg of unpeeled walnuts. The price before the crisis was 1.6 - 1.8 euros / kg. Tonnage from 100 hectares of walnut orchards (4 years old) is calculated on the basis of 3 t / ha. Total from 100 hectares. collecting 300 tons of dry walnuts. When splitting a nut, the output of a marketable kernel is 50%, that is, we get 150,000 kg. walnut kernels. The wholesale cost of a walnut kernel is about 4 euros / kg. The price before the crisis was up to 6 - 8 euros / kg. The siderat in the walnut garden can be a pumpkin before the crown of the trees closes. According to the adopted sowing scheme, the gross harvest of pumpkin from 100 hectares will be 2,000 tons. The minimum cost is 200 EUR / t.

Income from the sale of unpeeled walnuts after 4-5 years for 100-120 years will be: 300,000 kg. x 1.2 euros = 360,000 euros. Income can be increased by providing storage of the product for 3-4 months after harvest. When selling the kernel of a split nut (½ and ¼), the income will be :. 150,000 kg. x 6 euros = 900,000 euros. Additional income from the sale of pumpkin products from the first year of planting the garden will be: 2,000 tons x 100 euros = 200,000 euros Annually during the first 3-4 years.

EXPENSES 2015: - Expenses for the preparation of the project of the walnut orchard - 1200 euros. - Land preparation (plowing, harrowing, cultivation) - 11,000 euros. - Preparation of planting holes (digging, filling with fertilizer) - 1300 euros; - Purchase planting material(12,000 seedlings, the average cost of which is 18 euros.) - 216,000 euros. - Transportation, customs clearance of planting material to the landing site - 25,000 euros. - Planting seedlings, watering 11,000 euros. - Installation of a fence and a structure for the watchman - 48,000 euros. - Labor remuneration - 18,000 euros. Total: 331.500 euros.

2016: EXPENSES FOR THE MAINTENANCE OF THE GARDEN 1. Before the purchase of planting material (we accept the survival rate of 80%) - 43 200 euros. 2. Plowing, disking between rows (weed removal, moisture retention) - 3000 euros. 3. Plowing of the near-stem land (manually 5 UAH / unit) - 4100 euros 4. Irrigation (Delivery of 4 m3 of water - 250 UAH. We accept 0.5 m3 per tree) - 3250 euros. (further watering at your discretion); 5. Protection of the garden in spring and summer (average 5 months) - 3000 euros. 6. Insurance Total: 56 350

Expenses for sowing green manure - pumpkin variety "One hundred pounds": 1. Cost of seeds: seeding rate - 2000 seeds per hectare + 25% per 80 hectares = 16,000 seeds or 160 kg. x 60 UAH / kg. = 9 600 UAH 2. Sowing with the SBN-3 seeder 20 000 UAH. 3. Manual two-time weeding with hilling and forming a crown 620 people / day x 50 UAH = 31 000 UAH. 4. Top dressing, fertilizers, pest and disease control 12 000 UAH. 5. Pumpkin harvesting - UAH 62,000. 6. Pre-sale preparation, processing: 120 000 UAH. Total: 254,600 UAH = 26,000 euros Total 413,850 euros. of which 106 650 euros are the costs of the Ukrainian partner. Taxes and overheads are not taken into account (costs of the Ukrainian partner)

2017: Proceeds from the sale of pumpkin 200,000 euros. Reimbursement of costs for design, purchase of seedlings and creation of a garden (50%) - 240,200 euros. Total: 440,200 euros. Costs: Maintenance of the garden and pumpkin cultivation - 72,350 euros. Land rent, taxes, insurance - 41,150 euros. Loan repayment - EUR 307,200. Total 420 700

2018: Profit balance for 2017 - € 19,500. Proceeds from the sale of pumpkin 200,000 euros. Total: 219.500 Costs: Garden maintenance and pumpkin cultivation - 29,150 euros. Land rent, taxes, insurance - 42,000 euros. Purchase of equipment and construction of a walnut processing plant 100,000 euros. Total € 171,150

2019: Profit balance in 2018 - 48,350 euros. Proceeds from the sale of pumpkin 200,000 euros. Proceeds from the sale of the walnut 600,000 euros. Costs: Maintenance of the garden - 14,000 euros. Land lease, taxes, insurance - 42,000 euros. Purchase of equipment for automatic harvesting of walnuts in the garden.

Starting from 2020, income is 1,200,000 euros. 2. OBTAINING WALNUT CORE (Peeling, calibration, pre-sale preparation). 3. INTEGRATED PROCESSING OF WALNUTS (Production of nut butter and crushing of walnut shells for further use).

V last years many people are seriously thinking about. But which direction to take? What to take so as not to burn out? And how to start with minimal costs? Processing walnuts is one of the directions own business, which does not need large financial and labor costs.

Where to start a walnut processing business?

Since ancient times, walnuts have been treated for diseases, they have been restored to strength, it has fed humanity, so there is no doubt that it is in great demand, especially in Europe. Many people buy walnuts from various sources from the population that grows it. But very few people recycle it. The essence of the business idea, which will be discussed, is precisely in peeling nuts from the shell. After all, the price of a pure, packaged nut is several times higher than its value in the shell.

Processing should start with the fact that first you need to take these same nuts somewhere. You can, of course, grow them yourself, but you will have to wait 5-6 years before the first harvest. It is also a rather troublesome activity.

Therefore, buying nuts is much more promising and more profitable than growing them, especially since it is far from a fact that planted and grown trees will bring a good harvest.

How to choose equipment for walnut processing?

The processing itself consists in extracting grain from the shell of pre-split walnut. But cracking nuts by hand is a very long and complicated process. Fortunately, technology in our century does not stand still, so you can purchase the so-called nutcracker.

This machine splits the shells thanks to two shafts, which are driven by an electric motor through a gearbox. Therefore, you will also have to work with pens. A staff of 3-5 employees is required.

You can find a nutcracker (if you search well) for an average price of $ 700-800. There are, of course, advanced industrial machines worth 3-5 thousand dollars, but there is no point in buying them, since you simply will not be able to use their full potential at full capacity.

Also, to organize a walnut processing business, you will need non-residential premises for working and storing purchased raw materials. The ideal option would be the private sector, but in the absence of such, you will have to rent premises. It should be roomy and heated, since with a good flow of customers it will be necessary to work all winter.

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How much can you earn from a walnut processing business

Walnut processing, a business related to this occupation - we understand further. And now to the most delicious thing - profit calculation. The productivity of the simplest walnut burnishing machine is from a centner (100 kg) per hour. But the kernels still need to be pulled out of the shell. One person in a normal eight-hour working day, without much straining, is able to sort out 200 kg of nuts. So, when three employees work within one month (22 working days), 13.2 tons are released finished products(200 kg * 3 people * 22 days = 13200 kg).

Based on the calculation that to obtain 1 kg of peeled walnuts, approximately 3 kg of unpeeled walnuts will be required, it follows that processing will require about 40 tons of walnuts, the average cost of which is $ 1 per kg.

You can sell ready-made grain for $ 5. The price fluctuates depending on the variety of nuts and the integrity of the processed grain, for example, "butterflies" (halves of the kernel of a nut) are much more expensive, and grain, which does not even contain whole quarters, is considered the cheapest.
The wages are about 10 cents per kilogram of sorted nuts, or a dollar per 10 kg.

costs per month = 40,000 (purchase of a nut) + 0.1 * 13,200 (wages) = 41,320 dollars;
income per month = 5 * 13,200 = $ 66,000.

Total net profit 66000-41320 = 24680 dollars per month!

1 950 usd / pcs.

We offer walnut processing lines of various configurations and capacities.

Pre-calibration of the walnut is NOT REQUIRED!

On the line, the walnut goes through the following processing stages:

1. Splitting the walnut shell

2. Separation of the kernel from the shell, cleaning

3. Sizing of kernels into fractions

4. Aspiration - cleaning the kernel from dust, debris, small particles and small shells

Butterfly yield,%: 20 - 60

You can see and evaluate the operation of equipment for walnut processing by visiting us.

We manufacture equipment for walnut processing: calibrators, nutcrackers, walnut cracking machines, vibrating screens, aspirators, FULL CYCLE, Walnut processing line. Any configuration with your characteristics.

You can get more detailed information by calling. Line video: http://youtu.be/zByvJr8g8ys.

"NPP Service Pack" produces and offers industrial equipment for the processing of walnuts and hazelnuts of various capacities for large processing enterprises and for small businesses.

We offer machines for peeling nuts from green pericarp with subsequent washing and drying of nuts, nut calibrators, nut cracker machines of different types of walnut cracking, walnut kernel beaters from "dense" conveyors and inspection tables, vibro-calibration sieves with aspiration for sorting kernels (butterfly, quarter, eight, crumbs) and removal of shells, drying ovens and drying tanks "one and a half ton" vacuum packers for kernels, disintegrators for grinding walnut shells into crumbs for making pellets and for powder up to 40 microns for abrasive and cosmetics, etc.

European workmanship, European and North Korean components. Real Hardware Warranty-1 ...

2,900 - 3,000 usd / pc.

"NPP Service Pak". We offer the MKO-03 nut cracker, recognized by many experienced walnut processors as the best. The machine is designed to break the walnut shells to obtain the optimal amount of whole kernel. Machine productivity - 140kg / hour. "MKO-03" has many technological settings for working with nuts of different sizes, the machine breaks the nut shell at least six points, which allows to significantly increase the quality of splitting and obtaining a whole kernel. "MKO-3" consumes 0.55 kW and can operate from a 220V or 380V network, is equipped with reliable electronics and an Italian gear motor. MKO-03 is used both as a separate unit and in industrial lines for processing walnuts. We also manufacture equipment for the separation of nuts from the green pericarp with subsequent washing of the nuts, calibrators, vibrating sieves with aspiration for separating the shell and separating the kernel into fractions, pre-punching machines for working with the "chisel", inspection stations ...

We manufacture equipment for walnut processing. Our nut cracker machines give the optimum whole kernel and real butterfly production (75%). We also produce calibrators for nuts, vibrating sieves with the function of shell aspiration, beaters for kernels from chipped nuts such as "Cleaver" "Greedy" "Bone", sorting and bulkhead conveyors for 8 or more places, disintegrators for grinding shells into powder-flour, packers kernels.

We customize equipment, provide assistance with delivery anywhere in the world, perform commissioning, warranty, service.

Viber: +38 067 776 38 39; +38 050 257 45 35

Email: [email protected]

A line for processing (splitting and sorting) walnuts and hazelnuts is on sale. The equipment is located in Rostov-on-Don. Warranty service until October 2014.

Price: Negotiable

ALL QUESTIONS ONLY BY PHONES:

Brief description of equipment:

Machine for cracking walnut shells "MKO"

We present to your attention practically new equipment for processing walnuts and hazelnuts. PAY ATTENTION, the equipment is factory certified, has a technical passport. It is a line (full cycle) of processing - from calibration to packaging of the finished kernel. The line includes 5 machines that can work in a complex or separately. This equipment in a work shift processes more than 1000 kg of raw materials, a large% of the kernel yield! Individual units are capable of carrying out a volume of about 5-6 tons per work shift. The complex also includes 2 systems for cleaning (aspiration) from debris and shells. The main components of this line (motors, gearboxes) are made in Italy and have a guarantee. The price is negotiable, barter (exchange) is possible. You can find out all your questions by calling 89614106107, 89185210874 or e-mail [email protected] [email protected]