Ready-to-use potato products for Ukraine
Feasibility study and design for shelf-stable, convenient potato products, for a large local grower and trader.
The challenge
Just before the war broke out, a large Ukrainian potato grower and trader asked GPE for a feasibility study and design. The goal: potato products with a longer shelf life and more convenience, as an alternative to fresh, unpeeled packed potatoes.
Supermarkets and wholesalers were already asking for them, but there was no local supplier yet. Due to the pandemic and later the security situation, all talks with client and suppliers took place remotely after the first site visits.
The solution
GPE mapped every client requirement in a product and packaging matrix: more than 30 SKUs of cut sizes and packs, for potatoes alone. The line also had to handle carrots and onions.
For shelf life and food safety the choice fell on pasteurisation, using an Automated Batch Retort System instead of a continuous belt pasteuriser. It suits small and large packs, in vacuum film and in gas-flushed trays. This lets the client follow the market: from mainly fresh-cut product to at least 70% pre-cooked and pasteurised.
A combination of abrasive and knife peeling, a multifunctional cutting system for strips, wedges, dices, slices and skin-on product, and a double optical sorting step for the high standards of Western retailers. Finally, a 3D footprint of the new plant was drawn up with the main contractor.
The result
Due to the geo-political situation, large loans to make the required investment were not available. The client therefore chose to set-up a small production line partly re-using existing equipment in its current production facility. This line can start serving the actual market demand and allow for product development at reduced financial risk.
GPE supported the design of this line, assessed the quotes for a new knife peeler and optical sorter, and helped find a pre-owned pasteuriser suited to smaller capacities.
Facing a similar decision?
We are happy to think along about your project, without obligation.