Cornish Grower Embraces Automation To Remove Potato Packing Bottleneck

As part of a long-term strategy to build resilience, Cornish potato producer Pengelly Farms has significantly increased its packing efficiency and reduced reliance on manual labour by integrating automated case assembly and sealing equipment from Endoline Automation.

Image: Pengelly Farms

The family-run business, established in 1967, grows premium salad potatoes across 1,200 acres in West Cornwall, and supplies approximately 16,500 tonnes of produce annually to retailers, wholesalers, and foodservice customers in the UK and Europe. 

As the business scales and both production volumes and packing speeds increased, the longstanding producer identified a bottleneck at the end of the potato processing line at its Helston packhouse.

The challenge emerged following the modernisation of the farm’s packing operation with a high-speed Newtec chute loader. 

While grading and sorting capacities had been upgraded, the company’s traditional manual case assembly and sealing of heavy 10kg boxes struggled to match the pace of the new equipment.

As a seasonal business operating in an increasingly challenging labour market, Pengelly Farms concluded that simply adding more staff would not deliver the long-term efficiency gains required. 

Instead, it opted to automate the process through a partnership with UK end-of-line packaging specialist Endoline Automation. 

A key requirement for the project was integrating new automation technology without replacing existing grading and sorting equipment.

The result was to install Endoline’s 221 Case Erector and 613 Fully Automatic Case Sealer within a packing operation already equipped with Haith multi-size graders and Tomra 3A optical sorters.

The compact footprint of the case erector enabled it to be incorporated into the existing packing shed without the need for building expansion either. 

“Endoline Automation was extremely accommodating,” explained Pengelly Farms Technical Manager Ben Cavill. 

“Labour shortages meant we needed to automate this aspect of our potato packing line. But replacing our high end sorting and grading equipment was non-negotiable. Endoline worked around this. As a result, we are already exploring automating labelling and palletising with them,” Cavill added.

Image: Endoline Automation

Overcoming Packing Challenges

A key solution was the dual opposing vacuum technology used to form packing cases, which is unique to Endoline.

Pengelly packs its potatoes in heavy-duty corrugated cardboard cases to withstand the rigours of transporting 10kg loads throughout the UK, Ireland, and mainland Europe.

However, these twin-walled cases are notoriously difficult to automate – often resisting opening, which increases the risk of bridging, tearing, or machine jams in conventional automated systems.

Endoline’s 221 Case Erector system is designed to counteract the stiffness of the cardboard by applying equalised force from both sides during the opening process, thereby reducing the need for manual intervention and helping to maintain throughput.

“The dual opposing vacuum technology is especially beneficial when forming heavy-duty boxes,” noted Pengelly’s UK Sales Manager James Saywell. 

“It works by clamping each side of the case during the forming process, applying the same amount of pressure to simultaneously open it from both sides.”

Achieving Greater Consistency

The newly integrated equipment from Endoline has also reduced packaging waste; supporting sustainability and maintaining a consistent production flow to the final stage of the packing process. 

Cases are erected, the bottom sealed, and then transferred via an existing conveyor directly to the Newtec chute loader, creating a continuous process from grading through to filling.

By automating the final sealing stage, Pengelly aims to ensure each case leaves the packhouse in a consistent condition, regardless of production volumes or shift patterns.

“Handling 10kg boxes can be an arduous task,” pointed out Saywell. “Manual sealing is often the first place where quality control on fresh produce packing lines slips, particularly at the end of a long shift.”

Image: Endoline Automation

Building Long-Term Resilience

Pengelly’s latest investment forms part of a wider programme of infrastructure development at the Red Tractor and LEAF-accredited grower. 

In 2022, the business expanded its coldstorage facilities with an additional 1,800 tonnes of capacity, bringing total chilled storage space to 10,000 tonnes.

The combination of increased storage and greater packing efficiency is intended to give Pengelly more control over the quality of its 16,500-tonne yield throughout the year, while reducing its exposure to labour shortages.

With labour availability remaining a key concern across the fresh produce sector, Pengelly views automation as an important part of its long-term strategy.

“Through automation, Pengelly is ensuring we preserve our Cornish farming heritage for years to come,” emphasised Cavill.