The new FoodTools Tortilla Chip Line combines the TC-200 high speed chip cutter with conveying, tumbling, weighing, box filling and trafficking stations to be an all-in-one Tortilla Chip Processing Line. Integrating each step into one seamless process improves the throughput, removes manual steps and consolidates components into one easy to manage solution. Once installed and combined with box erecting and closing systems, this Tortilla Chip Line can process up to 5,400 lbs per hour and only requires 5 people to operate the entire line.
The TC-200 has been our flagship inline tortilla chip slicer for years. Flatbread producers often start with a TC-1 or TC-2 standalone chip cutter before making the investment in a fully inline chip slicer. Some facilities use multiple standalone units on the same line with the same operator to achieve their desired throughput, but the inline operation of the TC-200 removes manual time spent loading, positioning and actuating each machine each cycle.
Watch the step-by-step process of the Tortilla Chip Line here and continue reading for a description of each step in the process.
Tortilla Chip Line Steps
1. Load Conveyor
The first step of the Tortilla Chip Line is loading the conveyor. Tortilla rounds can be stacked into predetermined heights up to 7.5 inches either by hand or by a stacker and stored in trays. Racks can be loaded into the line by one operator for each conveyor. As the stacks are loaded they are indexed into the machine and staged for the next step. The loading conveyor is configured to allow for autoloading directly from the stacker to the TC-200 to completely eliminate manually loading.
2. Cut Round Into Chips
The continuous conveyor loads and indexes stacks of rounds into position using a laser guidance system. As soon as a cutting cycle is complete product lifters move the next two stacks into portioning position while the rest of the conveyor line is indexed forward. The stacks are set on the custom blade sets and pusher plates press down through the stack, slicing the rounds into predetermined numbers of chips. The cut chips are dropped onto a takeaway conveyor and moved to the next step.
3. Tumble Chips
The takeaway conveyor drops sliced chips into one of two large tumblers where the stacks are tumbled, separated and prepared for weighing and boxing.
4. Weigh Chips
The tumbled chips are dropped into a separator chute above the weighing system. Once the desired weight of chips is accumulated the weighing system opens and drops the chips into the case below.
5. Fill Cases
Boxes or cases are either manually or automatically erected and then loaded onto the case conveyor. Here they are indexed and staged for filling from the weigh station. As soon as a case has been filled a shaking agitator engages and results in an evenly filled box. After agitation the box is conveyed to the takeaway conveyor the next empty case is indexed into position. When the target weight of chips is achieved the weigh station drops them into the case.
6. Case Distribution
Once filled the cases are moved to a takeaway conveyor to be sealed and prepared for distribution.
The entire Tortilla Chip Line can be designed to fit into a specific flatbread or tortilla production process and steps like loading, conveying, tumbling and case distribution are built to the customer’s specifications and can be integrated inline with upstream and downstream processing.
To see how this system works for Easy Foods watch this Baking & Snack Case Study here.
