For processing walnuts are used different types equipment - from manual peelers to units specialized in deep processing of raw materials, including equipment for the production of oil and leaf extracts.
Growing walnut for sale
For example: 200 trees will be placed on 1 hectare. Expenses for soil treatment and site preparation, purchase and transportation planting material and fertilizers average $2500-3000. This figure will increase if walnut trees are taken care of (watering, crown formation, hilling, weeding, fertilizing) by a hired worker.
With an average yield of 18 kg per tree, 1 ha will produce at least 3.2 tons of fruit.
The purchase price for 1 kg of unshelled nuts is $1-$2, which gives an income of $3200-$6400. Thus, the investment will pay off in a couple of years, and in the future will give a net profit.
The maximum income comes from the sale of shelled kernels, especially halves (butterflies). If a kilogram of round timber costs an average of $0.9-$1.4, then a kilogram of peeled kernels costs $6.1-$6.8.
Risks
A walnut growing business does not guarantee a quick profit. Contrary to numerous articles on the Internet, it will not be possible to open your own processing plant in 5-6 years. This business plan is designed for the long term.
Its risks include weather conditions, pests and plant diseases. Changes in the temperature regime observed in recent years disrupt the natural timing of fruit ripening and reduce yields.
Reduces its pests (nut moth, codling moth) and diseases (white spot, bacteriosis). The fruits lose their marketable appearance and taste, in the worst case, it comes to the death of the plant, which requires the manufacturer to spend additional money on processing seedlings or buying new ones.
It is more profitable to organize the purchase of round timber from the population. This will save not only money, but also time.
In this case, the costs will be minimal, and you can earn money by selling the halves of the kernels peeled from the shell.
Main types of processing equipment
In small and medium-sized businesses, units are used for both primary (chopping) and deep processing of raw materials, which make it possible to obtain an extract from a green fruit, nut oil or tea from the leaves.
Peelers
The device in the form of a drum removes the pericarp, speeds up the processing of round timber and does not damage the shell.
At the same time, it washes away the iodine present in the green peel, preserving the light color of the kernel, and carries out a preventive washing of the fruit from dirt and dust.
Nut calibrator
Divides round timber into fractions by diameter before processing on nutcrackers that require raw material calibration, increasing the percentage of butterfly yield. It happens linear (with a flexible system of settings) and rotary (holes are fixed, cannot be adjusted).
Nutcrackers
Designed for accurate splitting of round timber, which ultimately determines the cost of production.
The nuts used in processing are divided into:
- Manual - characterized by a low level of profitability and productivity (up to 5 kg / h). Suitable for home use only.
- Mechanical - the calibrated round timber enters the bunker and falls under the press, which is actuated by a manual lever. The extraction rate of the nuclei is up to 30 kg/h. Used in home and small business.
- Electric – processes 50–200 kg/h. Applies to small and medium businesses.
- Industrial - core extraction speed - up to 1 t / h. They shell the round timber without pre-calibration, which saves time and money.
vibrating sieve
Above the split round timber enters the sieve, where it is separated into fractions. The unsplit nut is returned for a splitting. Butterflies, quarters and eighths are fed into the aspiration system to blow out shells, dust and third-party debris. At the end, both the shell and the kernels (depending on the fraction) enter a separate container.
Industrial lines
The walnut processing line is a complete turnkey solution for a start-up entrepreneur. In the basic version, it includes a calibrator, an industrial nut cracker, a splitting machine, tools for extracting the kernel, a vibrating sieve and a business plan.
Such a simple system allows processing up to 1.6 tons of raw materials per day. Depending on the wishes of the client, the line can be supplemented with a vibrating screen, an aspiration system, a belt conveyor.
Leading manufacturers of processing equipment
The leading equipment manufacturer in Europe is AMB ROUSSET (France). Since 1970 it has been producing powerful lines full cycle.
In the US, Jessee Equipment Manufacturing is the leader. Over its 60-year history, the company has earned a reputation as a manufacturer of high-quality and reliable equipment. The company is actively implementing various innovative technologies such as calibrating raw materials with a laser.
Technika-Rostov assembles modular equipment systems that are easy to install and transport and meet the requirements of each client. The great advantage of this manufacturer's products is its affordable price and after-sales service.
Today, walnut processing is developing, gaining momentum and attracting more and more people. Some who once tried themselves in the walnut business do not stop, but, on the contrary, increase the scale of walnut processing. And there are people for whom this business did not go well, the invested funds did not pay off and the walnut business came to naught. Why can walnut processing be curtailed, and what are the main reasons for a failed walnut business?
Main reasons why nut business"did not go"?
Poor quality raw materials. The most important product that you will deal with is walnut, and the main task at the first stage is the purchase of high-quality nuts. 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 a nut is purchased.
Walnut without sizing. Many nut growers skip such an important process as sizing the nut - sorting the nut by size for further high-quality splitting. We all know that there are few high-quality nuts in Ukraine and all the nuts that 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 under-split or, even worse, splitting, and the integrity of the kernel decreases.
*Important! When working with a non-calibrated 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, it is necessary to estimate how much walnut per day\week\month you plan to split, how many workers will work with the walnut and already then plan what kind of walnut processing equipment you need to buy. Often people are chasing fast splitting, high performance equipment, but not everyone understands that for different volumes of nuts, fast splitting can be reflected in different ways.
Recruitment of staff and pickers. When the main stages of processing have been completed - sizing and splitting the nut, the next, important, sorting, cleaning and sorting of the nut comes next. By hiring unskilled people or people "from the street", due to inexperience, you run the risk of getting not a qualitatively sorted whole core, but a split mix (quarters, halves, eights of the core).
Unequipped room for walnut processing. Highly important point in walnut processing, this is a room where not only equipment for sizing, splitting walnuts will be located, but also a place for drying walnuts, convenient workplaces for sorters, food containers and boxes for the kernel, a place for storing walnuts, etc.
Lack of sales contacts. The last but not least process is the sale of nuts after processing. Often, having no information where to sell the walnut, walnut growers send lots of walnuts to the market, where resellers buy walnuts at an inexpensive price, and then sell them twice as much.
How to avoid failure?
Buy only a quality nut, this season, pleasing to the eye, without cracks, uniform color and smooth shell. Trust trusted sellers, be sure to test the nuts before buying, selectively split a couple or three nuts from different parts of the bag, so you protect yourself from buying a “pig in a poke”. More Tips for buying a walnut, read here - Tips for buying a walnut.
Gauge the nut! This can be manual sorting of nuts by size, if there are not many nuts, or mechanical sizing of nuts by equipment. In any case, you will keep the core intact during splitting, avoid under-splits and, accordingly, additional manual reassembly. Buy walnut calibrator - Walnut calibrator.
Before starting work, estimate the volume of your production. If you are a beginner walnut grower, you have a small amount of walnut, then you should not chase high productivity and fast splitting. Start with small mechanical equipment, so master the splitting skills and keep the core intact. Work on electrical equipment with a small amount of walnut will not show a good result, but on the contrary, every flaw in the walnut 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 speed of processing at high level. Such nutcrackers can work without calibration, which will significantly reduce the cost of calibration equipment and speed up the splitting process.
For sorting, hire qualified people who have dealt with walnut sorting, they know all the nuances of walnut processing. Equip your staff with additional tools that will speed up the work of cleaning and sorting the nut, protecting the sorters from injury and cuts. If your business is just starting to develop, you can involve relatives in the work, so you will save on staff salaries and be sure of the quality and honesty of the work.
To optimize the workflow, it is necessary to equip the working room with everything necessary for the complete and efficient processing of walnuts. There should be an equipment area in the room where nutcrackers, calibrators, vibrating tables, etc. will be installed. Further, it is necessary to equip the area for working personnel - sorters, tables for sorting, lighting, additional tools for cleaning nuts, containers for kernels and recyclables. The better the workflow and space, the more efficient the work and the end result will be!
For the sale of a walnut, namely the kernel, it is necessary to establish sales contacts and find sellers who would buy it expensively. These people are easiest to find online. in social networks or on bulletin boards, where everyone has a higher and higher price. You can also find import partners there who are ready to buy walnuts from other countries, this option is much more profitable and profitable. Do not forget about waste - shells and partitions, you can also sell them and make money!
We see that the walnut business has its own nuances, mistakes and pitfalls that can pull back. However, following the advice and recommendations they can be avoided! Develop your walnut business with Orekhovod!
In recent years, many people have been seriously thinking about. But which direction to choose? What to take in order not to burn out? And how to start with minimal costs? Processing of walnuts is one of the directions own business, which does not require large financial and labor costs.
How to Start a Walnut Processing Business?
Since ancient times, walnuts have been treated for diseases, they have restored strength, they fed humanity, so there is no doubt that it is in great demand, especially in Europe. Many people buy the nut in various varieties from the population that grows it. But very few people process it. The essence of the business idea that will be discussed is precisely in the peeling of 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 begin 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. Besides, it's quite a hassle.
Therefore, it is much more promising and profitable to buy nuts than to grow them, all the more so - it is far from a fact that the planted and grown trees will bring a good harvest.
How to choose walnut processing equipment?
Processing itself consists in extracting grain from the shell of a previously split nut. But to crack a nut by hand is a very long and complicated process. Fortunately, technology in our age does not stand still, so you can buy the so-called nutcracker.
This machine splits the shell thanks to two shafts, which are driven by an electric motor through a gearbox. Therefore, the handles will also have to work. We need a staff consisting of 3-5 employees.
You can find a nutcracker (if you search well) at an average price of 700-800 dollars. There are, of course, advanced industrial machines worth 3-5 thousand dollars, but there is no point in buying them, since it simply will not be possible to use their full potential at full capacity.
Also, to organize a walnut processing business, you will need non-residential premises for work and storage of purchased raw materials. The ideal option would be the private sector, but in the absence of such, it will be necessary to rent the premises. It should be spacious and heated, because with a good flow of customers, it will be necessary to work all winter.
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How Much Can You Make From a Walnut Processing Business
Walnut processing, the business associated with this activity - we understand further. And now to the most delicious - the calculation of profits. The productivity of the simplest walnut polishing machine is from a centner (100 kg) per hour. But the kernels still need to be pulled out of the shell. One person for a typical eight-hour working day, without particularly straining, is able to sort out 200 kg of nuts. So, when three employees work for one month (22 working days), 13.2 tons of finished products come out (200 kg * 3 people * 22 days = 13200 kg).
Based on the calculation that to obtain 1 kg of peeled nuts, approximately 3 kg of unpeeled nuts will be required, it follows that about 40 tons of nuts will be required for processing, the average cost of which is $ 1 per kg.
You can sell finished 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 nut kernel) are an order of magnitude more expensive, and grains that do not even have whole quarters are considered the cheapest.
The pay is about 10 cents per kilogram of sorted nuts, or a dollar per 10 kg.
- costs per month = 40,000 (buying a nut) + 0.1 * 13,200 (wages) = $ 41,320;
- income per month = 5 * 13200 = 66000 dollars.
Total net profit 66000-41320 = $24680 per month!
- Calibrator-sorter
- walnut shelling machine
- Vibrating sieve calibrator
- Belt conveyor (inspection table)
Walnut Processing Line is a complete solution that consists of a set specially selected for the complete walnut processing cycle, in order to optimize the walnut processing process as much as possible and get a good indicator of the whole kernel.
Walnut Processing Line
The walnut sizing machine is rotary and is a design in the form of a working sectional drum with the required dimensions of the calibration holes in each section of the drum. The working drum is made of sieves with the required diameter of the calibration holes.
Rotary walnut sizing machine NRS-4M is used for sorting nuts by size.
- The productivity of the machine depends on the speed of rotation of the calibration drum and is 350 - 1200 kg/h. The rotation speed of the drum is set depending on required quality walnut size calibration.
- The drum consists of four calibration sections, each section has its own sorting hole diameters of 25, 30, 33 and 40 mm.
- By means of the regulator it is possible to control the speed of rotation of the calibration drum from 1 to 30 revolutions per minute.
- Supply voltage - 220 V. Power consumption - 1200 W.
- Machine weight - 472 kg. Dimensions - 5150 x 2220 x 1070 mm.
After the nut is calibrated, it must be split and from this stage its processing begins. The quality of the final product depends on how well the split was made, which affects the price.
Machines for splitting walnuts with the design of the unit for splitting, consisting of two piercing plates, have proven themselves very well. On this machine, it is possible to adjust the gap between the piercing plates, which allows you to get a high percentage of the whole core.
ODM - 994/250 Walnut shelling machine
- Designed for cracking nut shells in industrial quantities.
- Operating productivity of walnut peeling - 200-250 kg/h
- Adjustment of the gap between the pricking plates - from 0 to 5 mm
- Supply voltage - 380 V. Power consumption - 1.6 kW.
- Machine weight - 360 kg. Dimensions - 725 x 905 x 1690 mm.
After splitting, the nut enters the vibrating sieve, where it is sorted into fractions and partially shelled. With the help of a vibrating sieve, you can quickly and efficiently sort the walnut in industrial volumes. The vibrating screen is an integral part of the walnut processing line.
Vibrating sieve for sorting split nuts VSC-4N
- To calibrate chopped walnuts, the sieve is provided with three replaceable sieves with a sorting cell diameter of 18, 8 and 4x25 mm and a fixed sieve with cells with a diameter of 2x16 mm.
- Vibration is generated by two electric vibrators. When adjusting electric vibrators, you can control the vibration amplitude, 16.7 Hz, the oscillation frequency.
- With the help of an industrial hood with a power of 2.25 kW, the product is cleaned of debris.
- The productivity of the machine is 850 kg/hour.
- Supply voltage - 380 V. Power consumption - 3.5 kW.
- Machine weight - 800 kg. Dimensions 3957 x 2596 x 2563 mm.
The final processing of the nut is done by hand, so it is possible to achieve the best result and get a high percentage of the whole kernel. To optimize the process, inspection tables are used, the tape of which is divided into several sections, which allows the remains of the shell and nut kernels to move along different parts of the conveyor and pour into different containers.
Inspection table for split walnut SI-2
It is used to separate debris and shell residues from nut kernels, to transport them to a container. Sorting of the product is carried out by at least two operators, with the help of visual control.
- Conveyor belt type - food polyurethane.
- The number of levels of conveyor belts - 2 pcs.
- The productivity of the machine is 1000 kg/h.
- Supply voltage - 220 V. Power consumption - 0.8 kW.
- Machine weight - 250 kg. Dimensions 5400 x 1050 x 1600 mm.
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. The climatic conditions have so developed that far from every country a walnut can grow and ripen. In Ukraine, 120-130 yew grows annually. tons of walnuts and in this indicator only the USA and China can compete with Ukraine 460 yew. tons and 700 thousand. 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 this product (more than 80% of products are exported).
In any type of business, including small ones, the most important thing is profitability. Therefore, before you start 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%. This business is very big role plays the one to whom you will sell the finished product. 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 it is not so easy to reach foreign wholesalers, so many producers sell processed walnuts to domestic wholesalers.
Types of shelling.
When processing walnuts, there are several ways to peel them:
- manual cleaning;
- vacuum method;
- mechanical way;
- soaking with roasting;
- cleaning with the help of a calibrating - crushing apparatus.
Now let's look at each method in more detail.
Manual cleaning walnut from the shell is the most ancient method of cleaning, which has survived to this day. The profitability of this cleaning method is very low. People who are engaged in walnut peeling receive pennies at such enterprises, there is a very large turnover of staff and often people who have nowhere else to go, pensioners and the disabled, work. How does this cleaning method work? There are large tables at which the workers sit. There are large piles of walnuts in the middle of the tables. Near each worker there are containers for shells, quarters, halves and cuts. This type of cleaning has remained in China, we practically do not have such workshops.
Vacuum method peeling a walnut is already a more advanced method than manual processing. The technology is as follows: a walnut is 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 pressure drop, the walnut shell does not withstand and bursts.
Mechanical method of cleaning a nut. The technology of peeling a walnut is as follows: a walnut is poured into the bunker, then the walnut is fed to a press, which breaks the shell with the help of mechanical pressure on the walnut. The pressure on the press is adjustable, 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 culling is obtained, which the press simply crushed. You also need to constantly adjust the pressure, and this greatly slows down the process of peeling the walnut.
Roasted walnut soak. The technology is as follows: the nut is poured into a container with water and soaked for a while, after which 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 calibrating crusher, this is the most common type of walnut peeling. The technology is as follows: the walnut is sifted into fractions using a sizing sieve, then it is fed into the crusher along the conveyor belt. The crushing section has several sections for different fractions, or one, the size of which is adjusted depending on the fraction. The nut in the crusher splits and enters the winnower, which separates the shell from the kernel. Then the nut enters the sizing sieve, which separates the various fractions of the kernel.
It is worth noting that no matter what cleaning method you choose, do not forget that no matter what equipment you have, you still have to do some work manually. Alas, without it in any way.
Walnut processing: equipment.
Equipment for peeling and processing walnuts is quite expensive, so many novice businessmen make it with their own hands. If your finances allow, 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 puzzle over the development of new equipment. The approximate cost of the walnut peeling line is from 200 to 900 yew. dollars. This is of course not enough.
Walnut processing: purchase of raw materials.
Buying raw materials is the most important aspect of this small business. During the year, the price of round nuts varies greatly. The lowest cost in the season, and then the price increase right up to the next season. Therefore, large walnut processors buy large quantities during the 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 mode of maintenance so that the nut does not get wet and does not dry out. The purchase of raw materials can be carried out wholesale from large owners of walnut orchards, as well as from the population. Buying from orchards is good because the nut is of the same grade, 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 peeling. When buying a roundwood nut from the population, you will not save much, but the nut that you buy will be collected under different trees and will have to be more carefully sized. Also, when buying a nut from the population, one must not forget that there are such varieties of nuts in which the shell is thick and it peels 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 profit.
GOST standards according to which nuts are divided.
After splitting, nuts according to GOST standards are divided into the following categories:
- The Extra Class contains halves and quarters, but their content must not exceed 10%;
- The first grade allows the content of 15% of the total mass of nuts with a size of 1/8.
- Halves, this category includes halves of a nut, while their content must be at least 80% of the total mass. The remaining 20% are quarters and a core the size of three-quarter halves.
- Quarters.
Nut kernels are sorted on a sizing 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 the processing of walnuts, then you should think about creating your own garden. This will greatly reduce the cost of raw materials and make your company independent of anyone. Also a big plus is that you can plant nuts at your place. good quality, which will greatly facilitate the process of processing and calibration for you. For a garden, it is enough for you to rent 50 hectares of land from the state for 49 years. Of course, you will have to make a good financial investment, but the garden will fully pay for itself in 3 years. Also, you can not only sell shelled walnuts, but you can also sell round walnuts.
The article is located in the section: Business ideas with medium investments.
