Bundy Sort

Behind the Scenes at BundySort: An In-Depth Look at Macadamia Processing

Recently, Andrew took the office team on a visit to BundySort, providing an inside look at how macadamias are processed from arrival to sorting. This facility, designed and built by Dave Anderson, is a key part of the supply chain, ensuring that only the highest-quality macadamias make it to market. For those who couldn’t hear everything on the day, this blog post provides an expanded breakdown of what was covered in the tour, with deeper insights into the processes involved.

The BundySort Facility: A Critical Step in the Macadamia Supply Chain

BundySort plays a vital role in the macadamia industry by providing an efficient, high-volume sorting and cleaning system. Given that macadamia nuts arrive in various conditions—some pristine, others mixed with husks, sticks, and even debris—this facility is designed to handle all types of loads effectively.

The system starts with a truck unloading process that allows multiple loads to be received simultaneously. With three hoppers and two lines, the facility can handle a significant throughput—approximately 60 tonnes per hour unloaded and 15 tonnes per hour processed. This dual-line approach ensures minimal downtime and greater efficiency, especially during peak harvest periods when farms are bringing in large quantities of nuts daily.

Curing and Drying: A Critical Step for Long-Term Quality

Once cleaned, the macadamias enter the curing rooms, where they are dried under carefully controlled conditions. These curing rooms are essentially modified shipping containers, each fitted with powerful ventilation systems. The controlled curing environment is critical because moisture content must be precisely reduced to prevent spoilage and ensure optimal shelf life.

Key elements of the curing process include:

  • Controlled Humidity and Temperature: The facility maintains a relative humidity (RH) of approximately 55% and temperatures between 30-35°C. Maintaining the right balance of heat and airflow ensures the nuts dry uniformly without cracking or becoming overly brittle.
  • Energy Efficiency Through Heat Recovery: One of the innovative aspects of BundySort’s curing system is its ability to use heat from the ceiling cavity. Instead of relying solely on electrical heating, the system pulls in warm air from the roof cavity, significantly reducing energy costs. This sustainable approach is not only cost-effective but also aligns with the industry’s increasing focus on environmentally responsible farming and processing.

Advanced Sorting Technology: Ensuring Premium-Grade Macadamias

Once dried, the nuts move into an advanced sorting system that leverages both colour sorting and X-ray technology. These cutting-edge methods ensure that only high-quality nuts make it through to final processing:

  • Colour Sorting: The first phase of sorting involves high-speed cameras that detect defects based on external appearance. Any nut that appears too dark, has husk remnants or shows signs of damage is immediately removed.
  • X-ray Inspection: Even the best colour sorting systems can miss internal defects, which is why an X-ray scanner is used as the next line of defence. This technology detects hidden issues such as cracks, insect damage, or contamination, ensuring that only the best-quality nuts continue through.
  • Final Hand Sorting: Although the automated systems are highly accurate, human oversight remains essential. Workers manually inspect nuts to catch anything the machines might have missed, particularly when adjustments to the equipment settings are needed.
Around the Farms Bundy Sort by Macadamia Farm Management

Addressing Industry Challenges: Dirty Loads and Processing Delays

One of the major challenges in macadamia processing is dealing with ‘dirty’ loads—those that contain excessive amounts of non-nut material. These loads can be a mix of husk, dirt, sticks, rocks, and sometimes even small animals like frogs. The difference in processing time is significant:

  • A clean batch, harvested with a well-maintained pin-wheel harvester, can be processed in just 15 minutes.
  • A particularly dirty load, however, can take up to 8 hours to clear.

The new stick walker addition is expected to alleviate this issue, helping to pre-clean loads before they enter the main processing system. This will not only improve efficiency but also reduce downtime and operational costs.

The End Result: High-Quality Macadamias Ready for Market

After sorting, the nuts are consolidated and prepared for sale or further processing. The first round of sorting often contains lower-quality nuts, but as the system cycles through, the overall quality improves. This is particularly important for ensuring that macadamias meet the stringent standards required for export markets, where consistency and quality control are paramount.

Watch the Tour

For those who missed the tour or want a deeper understanding of the process, check out the embedded video below. While the video is informal, it provides a real-time look at the technology and processes in action.

BundySort stands as a testament to the precision and innovation required in macadamia processing. By leveraging advanced sorting technologies, sustainable energy practices, and continuous improvements, the facility ensures that each nut reaching consumers is of the highest quality.

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