the world of cashew november 2011

TTTHHHEEE WWWOOORRRLLLDDD OOOFFF CCCAAASSSHHHEEEWWW

OLTREMARE S.r.l

Via dellIndustria, 17/19 Zona Ind. Bargellino 40012 CALDERARA DI RENO (BO)

Tel.: +39-051-2988311

Fax: +39-051-2988333

WEB: www.oltremare.biz

E-mail: [email protected]

The World of Cashew - Oltremare Nov. 2011

Page 2

CCCOOOMMMPPPAAANNNYYY PPPRRROOOFFFIIILLLEEE

The Italian private company OLTREMARE S.r.l. was founded in 1960 and ever since it

has entirely devoted its activity to the cashew industry. The company started its activity in

processing cashew nuts in its premises of Zola Predosa Bologna Italy with the first

mechanical cashew processing plant ever built since then. OLTREMARE is now known as the

world-leading manufacturer of cashew nut processing plants and service provider for the

cashew business. Its keen and global knowledge of the cashew business is also an advantage

for the customers. OLTREMARE is opinion leader in cashew processing technology and in this

respect it has introduced many new original and effective techniques and solutions.

Over the years, in addition to plant production, OLTREMARE has broadened its

activities with the ultimate aim of promoting the potential wealth produced by cashew nuts.

Presently its activities are:

production, installation and commissioning of mechanical cashew processing plants

and related technical assistance;

feasibility studies (agricultural and industrial);

establishment and management of cashew plantations;

technical assistance and training in cashew cultivation.

On top of this OLTREMARE has added to its primary activity two more machinery lines

which complement and at the same time widen the scope of business:

engineering, production and installation of electronic colour sorting machines

engineering, production and installation of vacuum packing machines for bulk

commodities.

Since 1960 OLTREMARE has installed its plants in the following countries: BENIN,

IVORY COAST, TOGO, NIGERIA, KENYA, TANZANIA, MOZAMBIQUE, GUINEA BISSAU,

MADAGASCAR, BRAZIL and VENEZUELA. More recently OLTREMARE has taken up projects in

Asia and in particular VIETNAM, INDONESIA, REPUBLIC OF THE PHILIPPINES, PEOPLES

REPUBLIC OF CHINA, THAILAND and INDIA.

OLTREMARE implemented some project with the financing of international institutions

such as ADB (African Development Bank), WB-IDA (World Bank International Development

Association), EDF (European Development Fund), IFC (International Finance Corporation), CDC

(Commonwealth Development Corporation), EIB (European Investment Bank), and with the

General Directorate of Cooperation of the Italian Ministry of Foreign Affairs. Other customers

are private companies whose projects have been financed through loans by international

commercial banks.


Page 3

OOOLLLTTTRRREEEMMMAAARRREEE RRREEEFFFEEERRREEENNNCCCEEESSS

INDUSTRIAL PROJECTS

1964 TANITA

Country : Tanzania

Supply : Cashew nut processing factory with

12,000 tons/year capacity

Customer : TANITA LTD.

1966 MOCITA

Country : Mozambique



Customer : INDUSTRIAS DE CAJU MOCITA S.A.R.L.

1969 MONAPO




Customer : COMPANHIA DO CAJU DO MONAPO

S.A.R.L.

1971 ANTENES




Customer : INDUSTRIAS DE CAJU ANTENES S.A.R.L.

1973 KILIFI

Country : Kenya



Customer : KENYA CASHEW NUTS LIMITED

1973 PARAKOU

Country : Benin



Customer : SOCIT NATIONALE FORESTIRE

(S.NA.FOR.)

1974 TANITA II

Country : Tanzania




1976 SOUTHERN TANZANIA PROJECT - LINDI

Country : Tanzania



Customer : CATA (Cashew nut Authority of

Tanzania)

1976 SOUTHERN TANZANIA PROJECT - MTAMA

Country : Tanzania




Tanzania)

1976 SOUTHERN TANZANIA PROJECT - MASASI

Country : Tanzania




Tanzania)

1977 SOUTHERN TANZANIA PROJECT - NEWALA

Country : Tanzania




Tanzania)

1977 KORHOGO

Country : Ivory Coast



Customer : A.I.C.I. (Anacarde - Industrie - Cte -

dIvoire)

1978 SOUTHERN TANZANIA PROJECT -

NACHINGWEA

Country : Tanzania




Tanzania)

1978 PARIAGUAN

Country : Venezuela



Customer : CAIMECA (Complejo Agro-Industrial de

Merey CA)

1980 TUNDURU

Country : Tanzania




Tanzania)

1981 LAMA-KARA

Country : Togo



Customer : TOGOFRUIT

1984 UVINZA

Country : Tanzania

Supply : Salt processing factory with 60,000

tons/year capacity

Customer : NYANZA SALT MINES


Page 4

1986 TANITA I & TANITA II

Country : Tanzania

Supply : Rehabilitation of cashew nut processing

factories previously supplied.

Assembling and technical assistance.


1986 KILIFI

Country : Kenya

Supply : Rehabilitation of a cashew nut

processing factory previously supplied.

Assembling and technical assistance.

Customer : KENYA CASHEW NUTS LIMITED

1987 MAJUNGA

Country : Madagascar

Supply : Turn-key cashew nut processing factory

with 3,850 tons/year capacity.

Technical assistance and training.

Customer : FA.MA.MA.

1987 IBADAN

Country : Nigeria


780 tons/year capacity. Frying, salting

and packing unit. Technical assistance.

Customer : TRANS INVESTMENTS COMPANY LTD.

1989 BISSAU

Country : Guinea Bissau

Supply : Cashew nut processing factory with a

capacity of 1,500 tons/year. Technical

assistance.

Customer : GETA BISSAU

1990 SURABAYA

Country : Indonesia


2,350 tons/year capacity. Marketing

and technical assistance.

Customer : P.T. INPANIDA CEMERLANG

1991 CUCHI DISTRICT

Country : Vietnam


1,500 tons/year capacity. Technical and

marketing assistance.

Customer : INEXIM

1991 HO CHI MINH CITY

Country : Vietnam

Supply : Cashew nut processing basic machinery

with 400 tons/year capacity. Local

personnel training.

Customer : F.A.O. and Ministry of Forestry of the

S.R. Vietnam

1992 UJUNG PANDANG

Country : Indonesia


4,200 tons/year capacity. Training,

marketing and technical assistance.

Customer : P.T. CITRA SEKARWANGI AGRO

PERSADA

1992 KORHOGO


Supply : Rehabilitation of a cashew nut

processing factory with 1,500

tons/year capacity.

Customer : ANACARDE INDUSTRIE

1993 NACALA



capacity of 6,000 tons/year

Customer : COMPANHIA DO CAJU DE NACALA

1994 UJUNG PANDANG

Country : Indonesia



Customer : P.T. SETIA JITA PRATAMA

1995 NANSHA

Country : P.R. of China

Supply : Machinery for cashew nut processing.

Capacity 2,000 tons/year

Customer : U.T.C. HOLDINGS (H.K.) CO. LTD.

1995 LUMBO




Customer : INDUCAJU S.A.R.L.

1995 KWALE

Country : Kenya



Customer : KWALE CASHEW PROCESSORS LIMITED

1996 XAI-XAI



capacity of 8,500 tons/year

Customer : ANGLO AMERICAN CORPORATION OF

SOUTH AFRICA LTD.- MOCITA

11999999 TTEERREESSIINNAA

Country : Brazil

Supply : Cashew kernels processing plant with

350 cases per day capacity

Customer : EUROPA INDUSTRIA DE CASTANHA

LTDA

22000000 FFOORRTTAALLEEZZAA

Country : Brazil

Supply : Cashew nut processing machinery

Customer : RESIBRAS


Country : Brazil


1000 cases per day capacity

Customer : USIBRAS


Page 5

2001 QUILON

Country : India


Customer : OLAM EXPORT INDIA LTD


Country : Brazil


Customer : IRMAOS FONTENELE SA

2001 FORTALEZA

Country : Brazil


Customer : CIONE

2001 QUILON

Country : India


Customer : WESTERN INDIA CASHEWS LTD


Country : Brazil


Customer : IRACEMA IDUSTRIA DE CAJU (KRAFT FOODS)

2001 FORTALEZA

Country : Brazil


Customer : EMPESCA ALIMENTOS SA

22000011 CCAASSCCAAVVEELL

Country : Brazil


Customer : CASCAJU AGROINDUSTRIAL SA

22000011 MMOOSSSSOORROO Country : Brazil


Customer : A.FERREIRA

22000022 QQUUIILLOONN

Country : India


Customer : QUILON FOODS

22000033 LLAAMM DDOONNGG PPRROOVVIINNCCEE

Country : Vietnam

Supply : Cashew kernel processing plant

Customer : CAI LAN OILS & FATS INDUSTRY CO.

LTD.

22000044 TTEERREESSIINNAA

Country : Brazil


Customer : FONCAPI


Country : Brazil


Customer : UNICA


Country : Brazil


Customer : CAJU GOMES


Country : Brazil


Customer : AMENDOAS DO BRASIL


Country : Brazil


Customer : RESIBRAS


Country : Brazil


Customer : UNICA


Country : Brazil


Customer : USIBRAS

22000055 DDAARR EESS SSAALLAAAAMM

Country : Tanzania


Customer : OLAM TANZANIA LTD.


Country : Brazil


Customer : OLAM DO BRASIL LTDA


Country : Brazil


Customer : RESIBRAS


Country : Brazil


Customer : RESIBRAS


Country : Brazil


Customer : IRACEMA


Country : Brazil


Customer : USIBRAS


Country : Tanzania




Page 6

2006 HO CHI MINH CITY

Country : Vietnam


Customer : OLAM VIETNAM LTD.

22000077 MMAACCIIAA



Customer : MACIA CASTANHA DE MOCAMBIQUE

22000077 IINNHHAAMMBBAANNEE



Customer : ANACARDIA LDA


Country : Tanzania


Customer : BUCO INVESTMENT HOLDINGS

TANZANIA


Country : Brazil


Customer : RESIBRAS

22000077 TTAANN PPHHUUOOCC VVIILLLLAAGGEE

Country : Vietnam


Customer : NAM LONG COMPANY LTD

22000077 HHOO CCHHII MMIINNHH CCIITTYY

Country : Vietnam


Customer : SAIGON CASHEWS

22000077 BBIIEENN HHOOAA CCIITTYY

Country : Vietnam


Customer : DONAFOODS

22000077 AANN BBAAII CCOOMMMMUUNNEE

Country : Vietnam


Customer : THAI BIN INVESTMENT

22000077 HHOOAA LLOOII TTOOWWNN

Country : Vietnam


Customer : NHAT HUY

22000077 TTAANN AANN TTOOWWNN

Country : Vietnam


Customer : TANIMEX

22000077 PPHHAANN RRAANNGG PPRR--TTCC

Country : Vietnam


Customer : NITAGREX

22000077 TTHHUU DDAAUU MMOOTT TTOOWWNN

Country : Vietnam


Customer : HAI LONG CO.

22000077 SSUUOOII CCAATT CCOOMMMMUUNNEE

Country : Vietnam


Customer : XUAN LOC PHAT

22000077 PPHHUUOOCC BBIINN TTOOWWNN

Country : Vietnam


Customer : TRINH THI KIN NGUYET

22000077 TTUUYY HHOOAA CCIITTYY

Country : Vietnam


Customer : PYGEMACO LTD.

22000077

Country : Vietnam


Customer : LANDOAN CO. LTD.

22000077 CCAAMMLLAAMM TTOOWWNN

Country : Vietnam


Customer : HOAPHAT CO. LTD.

22000077 MMIINNHHHHUUNNGG CCOOMMMMUUNNEE

Country : Vietnam


Customer : MAI HUONG CO. LTD.

22000077 TTUUYYAANN DDIISSTTRRIICCTT

Country : Vietnam


Customer : THIEN TAN JOINT STOCK CO.

22000077 BBIINNHHDDUUOONNGG PPRROOVVIINNCCEE

Country : Vietnam


Customer : TIN DAT CO.

22000077 CCAAIIRROO

Country : Egypt


Customer : EL WATANY GROUP FOR FOOD

INDUSTRY

22000077 AA.. PPLLUUEEKKDDAANNGG RRAAYYOONNGG

Country : Thailand


2.332 tons per year capacity

Customer : THAI KO FOODS CO. LTD.

22000077 NNAAMMPPUULLAA



Customer : CONDOR LIMITADA


Page 7

2007 NAMPULA



Customer : CONDORNUTS INDUSTRIA PROCESSAMENTO DE CAJU LTDA

22000077 TTCCHHAAOOUURROOUU

Country : Benin


Customer : WHITE BIRD INTERNATIONAL


Country : Tanzania




Country : Brazil


Customer : CIONE COMPANHIA INDUSTRIAL DE

OLEOS DO NORDESTE


Country : Brazil


Customer : CASCAJU AGROINDUSTRIAL S.A.


Country : Vietnam


Customer : RALS INTERNATIONAL VIETNAM CO.

LTD.

22000077 DDOONNGGHHOOAA DDIISSTTRRIICCTT

Country : Vietnam


Customer : DUY TAN CO. LTD.

22000077 EEAAKKNNOOPP TTOOWWNN

Country : Vietnam


Customer : HUYPHUC CO. LTD.

22000077 DDAALLAATT CCIITTYY

Country : Vietnam


Customer : LADOFOODS


Country : Vietnam


Customer : DUYTHAO


Country : Vietnam




Country : Vietnam



LTD.

22000088 TTUUTTIICCOORRIINN 11

Country : India


100 tons per day capacity

Customer : RAJKUMAR IMPEX PVT LTD.


Country : India



Customer : RAJKUMAR IMPEX PVT LTD.

22000088 TTAANNAANN TTOOWWNN

Country : Vietnam


Customer : LAFOOCO JOINT STOCK CO.

22000088 BBIIEENN HHOOAA CCIITTYY

Country : Vietnam


Customer : DONAFOODS

22000088 SSOONNGGIIAANNGG CCOOMMMMUUNNEE

Country : Vietnam


Customer : SON LONG

22000088 SSUUOOII CCAATT CCOOMMMMUUNNEE

Country : Vietnam


Customer : XUAN LOC PHAT

22000088 BBIINNHHDDUUOONNGG PPRROOVVIINNCCEE

Country : Vietnam


Customer : TIN DAT CO.


Country : Tanzania


Customer : AGRO FOCUS T. LTD.

22000088 TTCCHHAAOOUURROOUU

Country : Benin


Customer : WHITE BIRD INTERNATIONAL

22000088 MMAANNJJAACCAAZZEE



Customer : MADECAJU LDA

22000088 BBAANNFFOORRAA

Country : Burkina Faso


Customer : SOTRIA B SARL

22000088 MMAAPPUUTTOO



Customer : GLOBAL TRADING AND AGENCY BV


Page 8




Customer : CETA CONSTRUO E SERVIOS SARL

22000088 TTAANN TTHHAANNHH AA

Country : Vietnam

Supply : Cashew nut processing factory with 50

tons per day capacity

Customer : RALS INTERNATIONAL SINGAPORE




Customer : GLOBAL TRADING AND AGENCY BV


Country : Vietnam




Country : Brazil


Customer : USIBRAS

22000088 KKOOLLLLAAMM

Country : India


Customer : ASIATIC EXPORT ENTERPRISES

22000088 PPHHAANN RRAANNGG

Country : Vietnam


Customer : NITAGREX

22000088 VVIISSHHAAKKHHAAPPAATTNNAAMM

Country : India


Customer : OLAM EXPORTS (INDIA) LTD.

22000088 NNAAMMPPUULLAA



Customer : INDO AFRICA IMPORT EXPORT

22000088 TTHHUU DDAAUU MMOOTT TTOOWWNN

Country : Vietnam


Customer : TTP TRAN THIEN PHUC CO. LTD.


Country : Brazil


Customer : CIONE COMPANHIA INDUSTRIAL DE

OLEOS DO NORDESTE

22000099 VVIISSHHAAKKHHAAPPAATTNNAAMM

Country : India


Customer : OLAM EXPORTS (INDIA) LTD.

22000099 BBEENNCCAATT DDIISSTTRRIICCTT

Country : Vietnam


Customer : THIEN AN THINH PHAT CO. LTD.

22000099 TTAANN TTHHAANNHH DDIISSTTRRIICCTT

Country : Vietnam


Customer : NAM LONG CO. LTD.


Country : India


Customer : RAJKUMAR IMPEX PVT. LTD.

22000099 MMIIMM,, BBRROONNGG AAHHAAFFOO

Country : Ghana


Customer : MIM CASHEW AND AGRICULTURAL

PRODUCTS


Country : Brazil


Customer : RESIBRAS

22000099 TTAAYYNNIINNHH TTOOWWNN

Country : Vietnam


Customer : TAN VIET THAN CO. LTD


Country : Vietnam


Customer : OLAM VIETNAM CO. LTD


Country : India


Customer : WESTERN INDIA CASHEW CO. LTD.

22000099 KKEERRAALLAA

Country : India


Customer : KERALA NUT FOOD INDIA

22000099 BBOOUUAAKKEE




Customer : OLAM IVOIRE SARL

22001100 IILLOORRIINN

Country : Nigeria



Customer : OLAM INTERNATIONAL PTE LTD

22001100 GGUURRGGAAOONN

Country : India


Customer : OLAM AGRO INDIA LTD.


Page 9


Country : Vietnam


Customer : OLAM VIETNAM CO. LTD.

22001100 TTAANN TTHHAANNHH BB

Country : Vietnam




LTD.

22001100 TTEECCHHIIMMAANN

Country : Ghana


37,5 tons per day capacity

Customer : RAJKUMAR IMPEX GHANA LTD.

22001100 SSHHAANNDDOONNGG PPRROOVVIINNCCEE

Country : Peoples Republic of China Supply : Cashew nut processing machinery with


Customer : WASDON AGRICULTURAL INDUSTRY

PARK CO. LTD.

22001111 AANNDDRRAA PPRRAADDEESSHH AA

Country : India




22001111 LLOONNGG AANN

Country : Vietnam




LTD.

22001111 AANNDDRRAA PPRRAADDEESSHH BB

Country : India





Country : India



22001111 AABBIIDDJJAANN



Customer : AM EXPORT

22001111 MMAAPPUUTTOO AANNDD NNAACCAALLAA



Customer : INTRACO SPA (Commodity Aid of the

Italian Government to Mozambique)


Country : Vietnam



LTD.


Country : India




Page 10

PROJECTS - STUDIES SURVEYS

Country : CAMEROUN

Year : 1976

Title : Preliminary mission and study for the establishment of 100 ha pilot

plantations Authority : Ministry of Foreign Affairs Department

for Development Cooperation - Rome,

Italy - Ministry of Agriculture, Yaound

Country : TOGO

Year : 1976

Title : Rapport sur les plantations danacardiers au Togo

Customer : TOGOFRUIT - Lom

Country : SENEGAL

Year : 1977

Title : valuation de ltat actuel des plantations danacardiers

Authority : Ministry of Foreign Affairs Department


Italy

Country : KENYA

Year : 1980

Title : Preliminary study on the present and potential conditions of cashew

cultivation in the Coastal Region of

Kenya Authority : National Cereal and Produce Board,

Nairobi

Country : MOZAMBIQUE

Year : 1981

Title : Preliminary study for a feasibility project on present and potential

condition of cashew cultivation in Cabo

Delgado Province Authority : Ministry of Agriculture, Maputo

Country : KENYA

Year : 1982

Title : Feasibility study for the development of cashew nut production in the Coast

Region of Kenya Authority : Ministry of Agriculture, Nairobi -

Ministry of Foreign Affairs Department


Italy

Country : MADAGASCAR

Year : 1982

Title : tude de faisabilit du complexe industriel-anacardier de Majunga-

Ambilobe Authority : Ministre du Dveloppement Rural et

de la Reforme Agraire - Antananarivo

Country : SSEENNEEGGAALL

Year : 1983

Title : Projet de dveloppement de la culture danacardiers en Moyenne Casamance

Authority Ministre de la Protection de la Nature,

Dakar - AGRICONSULTING, Rome, Italy


Year : 1984

Title : Pilot project for cashew cultivation development with intercropping in

Macomia District - Cabo Delgado

Province Authority : Segretaria de Estado do Caju, Maputo -

Ministry of Foreign Affairs, Department

for Development Cooperation - Rome ,

Italy

Country : NIGERIA

Year : 1988

Title : Oyo State cashew farms survey Customer : Cashew Nut Processing Industries PLC,

Ibadan

Country : NIGERIA

Year : 1989

Title : Republic of Nigeria - Imo-State cashew-farms survey

Customer : Zogis Industries - Ibadan

Country : PEOPLES REPUBLIC OF CHINA Year : 1989

Title : Feasibility study on cashew cultivation and processing in the island of Hainan

Authority : Sino-Italian Cashew Development

Corporation -Hong Kong

Country : VIET NAM

Year : 1991

Title : Report on cashew industry in Viet Nam - Agricultural, Processing, Marketing

Authority : Ministry of Agriculture - Hanoi


Year : 1994

Title : Mozambique: Cashew Nut Project Authority : I.F.C. International Finance

Corporation, Washington D.C. - U.S.A.

Country : INDONESIA

Year : 1990s

: Various surveys for private companies


Page 11

PUBLICATIONS

- "Cashew Cultivation" 1977

- "Abstracts on Cashew" 1986

- "The World Cashew Economy" 1987

- "Cashew Cultivation Handbook" 1990

- Publication of a booklet in Kiswahili

language to be spread among Tanzania

farmers 1991

- "The World Cashew Economy 1994 ( second edition)


Page 12

PPPRRROOOCCCEEESSSSSS FFFLLLOOOWWW CCCHHHAAARRRTTT

SHELLS

TESTA

CNSL TO

MARKET

FOREIGN

MATTERS

STONES

AND SAND

FOREIGN

MATTERS


Page 13

GGGEEENNNEEERRRAAALLL IIINNNFFFOOORRRMMMAAATTTIIIOOONNN OOONNN

OOOLLLTTTRRREEEMMMAAARRREEE PPPRRROOOCCCEEESSSSSSIIINNNGGG SSSYYYSSSTTTEEEMMM

OLTREMARE PRODUCTION PROCESS

As regards the processing stages, please also refer to the Process Flow Chart above.

The OLTREMARE mechanical processing of cashew nuts involves the following stages:

1 - Cleaning and calibration

2 - Washing and humidification

3 - Roasting, centrifugation and cooling

4 - Shelling and pneumatic separation of the shells

5 - Drying

6 - Peeling, grading and sorting

7 - Packing

1 - Cleaning - Calibration

The bags are individually taken from the warehouse, then opened and emptied into the

feeding hopper. By means of a dosing feeder they reach the cleaning unit, pass on a vibrating

screen, and through an aspirator that removes dust and other foreign matters (leaves, twigs

etc.). The nuts pass then through an 8-size calibrator and are stocked by grade.

2 - Washing and Humidification

Before processing, the calibrated nuts go through the washing unit. After washing the

nuts are placed in the humidification area where they are regularly wet to obtain the required

moisture content before proceeding to the following roasting section.

3 - Roasting - Centrifugation - Cooling

The nuts are unloaded into the feeding hopper and carried by the bucket elevator into

the kiln hopper. There from, they are fed into the roasting kiln by a dosing feeder. The nuts

are conveyed to the bottom of the tank, where they expel the CNSL housed inside their shells,

thanks to the high temperature of the CNSL bath (190-200C). After crossing the bottom of the

roasting tank, the nuts get back to the surface and fall into the paddle elevator, which

discharges them into the centrifuges. While passing through the centrifuges, the CNSL is

drained from the nuts, then the latter are conveyed through a cooling tunnel into hoppers

placed before the shelling lines.

4 - Shelling and Pneumatic Separation of Shells

The nuts are discharged from the conveyors onto the footbridge hoppers feeding the

automatic shelling machines. Inside the shelling machines, the shell is split into two halves

and partly separated from the kernel. Both kernels and shells fall into the vibrating screen

placed underneath. This screen allows the kernels to drop on a conveyor belt as the shells and


Page 14

unshelled nuts remain on the upper side until the end of the shelling line. The empty shells

are sucked by an aspirator, the unshelled nuts proceed to separation benches.

The kernels are then cleaned and passed through the supercalibrator where whole,

broken and rotten kernels are separated. Whole and broken kernels are stored into separate

containers to feed the dryer.

5 - Drying

This operation is done to reduce the kernel moisture up to 3.5-4% for the following

mechanical peeling operation. The working temperature is around 80-85C. The discharged

kernels are kept in a cooling room.

6 - Peeling Grading and Sorting

The whole kernels are passed through a rocket peeler which is a cylinder provided of a

central bar fitted with springs. The cylinder and the central bar rotate in opposite directions

thus facilitating the separation of the testa from the kernels. All the kernels pass through a

supercalibrator where they are divided into whole and broken kernels. Unpeeled kernels are

sent to the air peeler. After one passage into the air peeler, almost the total production is

completely peeled. The small fraction that is not peeled completely goes for a second

passage into the air peeler and eventually to the manual finishing. The broken kernels

proceed to a pneumatic blower for final cleaning before entering a grading cylinder. Whole,

peeled kernels, and graded peeled pieces are sent to the optical sorting for separation of

scorched and dessert from white ones.

7 - Packing

After the grading operations, the kernels are vacuum packed, by grade, into plastic

bags, and then put in 50-lb. carton boxes.


Page 15

SPECIFIC CALIBRATION SYSTEM

PERFORMANCES

PRECISE CALIBRATION

HIGHER

PERCENTAGE OF

WHOLES

EASIER AND FASTER

KERNEL GRADING

PROCESSING IN

ACCORDANCE WITH

MARKET

REQUIREMENTS


Page 16

A SPECIFIC CALIBRATION


Page 17

Picture 1 Raw cashew nut calibrator


Page 18

ROASTER

1. Charging Hopper and Elevator

The hopper is placed below the ground level and it is made of electro-welded carbide

steel. A dosing vibrator for nut extraction is mounted at the bottom of the hopper. The dosing

unit is mounted on springs with oscillating blades and it is controlled by an electro-magnet.

The latter rests on a cast-iron support, which is bolted to a heavy cast constituting the base of

the dosing unit. The base and the springs on which the channel is mounted are engineered to

absorb the vibrations transmitted to the channel itself. The moisturized nuts are fed into the

kiln loading hopper by a bucket elevator whose structure consists of electro-welded steel

modules. The buckets are made of galvanized cast-iron, and are riveted to the PVC belt. The

driving head and the idle head are machine-tool manufactured steel-castings.

2. Continuous Roaster

A destoning device is placed at the entrance of the roaster for the extraction of stones

and other heavy foreign materials dangerous for the roaster operation. The system is

composed by a special feeding section made in carbide steel and a ventilation fan that lifts

the unit and lets the heavy foreign matter to fall into a collecting hopper. The lifting capacity

of the fan can be controlled by an inverter so to adapt the separation to the size of the nuts.

Another component is a roasting tank filled with CNSL, made of carbide steel, and duly

insulated to increase the efficiency, The tank can hold 5 m3

of CNSL maintained at a given

temperature by a heat exchanger placed at the bottom of the tank. The exchanger works with

diathermic oil heated by a shell burner. The CNSL inside the tank is stirred to increase the

thermal exchange.

A lath conveyor (catenary) feeds the nuts inside the tank, driven by a speed variator

determining the roasting time. The CNSL temperature inside the tank is maintained constant

by a diathermic oil flux regulator, which is controlled by a thermometer. The nuts are directly

unloaded into the centrifuges without the use of any elevator.

An overflow control device is placed on the tank side to keep the CNSL level constant,

and discharging the excess quantities into a decantation tank.

There is then a diathermic oil heating system composed by heat exchanger, circulation

pump, smoke extraction fan and valve, modular three-way valves, pressure switch, pressure

gauge on pipe coils, inlet and outlet, interception valve in stainless steel and pump protection

filter.

An aspiration hood collecting the roasting fumes is placed over the tank.

The roaster is provided also with an electric control panel with temperature control

and inverters.

Functioning data:

nut roasting capacity: 2500 kg/h

installed power: 10 kW


Page 19

diathermic oil flow rate: 50 m3/h

diathermic oil temperature: 300C

diathermic oil pressure: 500 mm/H2

O.

3. Aspiration and Fumes Circulation in the Kiln

An electro-welded steel pipe is placed on top of the aspiration hood collecting the CNSL

fumes. The fumes are blasted by a fan at the end of the pipe. A unit to collect the condensed

hot smokes is mounted on the exit line for the fumes, which, thanks to an underground pipe,

are finally released outside the unit through a brick chimney.

CONTINUOUS CENTRIFUGE

The centrifuge is an extractor draining the CNSL from the roasted cashew nuts. The machine

is composed of:

a) main structure

b) differential unit

c) scroll for nuts and filter basket

a) Main Structure

This structure supports the differential unit and in the same time allows nuts and

CNSL canalization into two different discharge outlets. The basic frame of the machine is

made of electro-welded steel sections and, through appropriate vibration-damping devices, it

supports the bull ring of the main structure. The latter is built with welded steel, Inside there

is the CNSL collector and outside, the hollow space let the drained nuts pass. Over said

structure, there are the nut collector and cover.

b) Differential Group

The group is composed of a hard alloy cast iron box Gh25, fastened to the a.m. main

structure. Inside the differential box primary and secondary shafts are assembled. They give

differential motion to the scroll and basket. They are made of alloy steel with inserts of AISI

304 steel. The gears are assembled on the shafts (made of alloy steels with nickel-chrome).

The gears are engaged with the planet wheels sustained by the two planet wheels carrying

plates. All gears are subject to case-hardening, hardening and grinding treatments. A pump

driven by the primary shaft, ensures lubricating oil circulation, whose temperature is kept to

the desired level by a cooling group outside the machine. The motion is given to the group by

pulleys and V-belts.

c) Scroll for Nut and Filtering Basket

The main and secondary shafts carry, as previously said, the filtering basket. The scroll

allows in the axial area the passage of nuts coming from the roasting section, and raise them

outside, and so it drains them. This frame is made of alloy electro-welded steel, and it uses


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special wear-resistant steels and alloy steels. The filtering basket is made of galvanized

carbide steel.

Picture 2 Roaster

Picture 3 - Centrifuges


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AUTOMATIC SHELLING-SEPARATION

PERFORMANCES

SINGLE NUT KNIFE

CUTTING SYSTEM

MORE BUTTS & SPLITS

LESS SMALL PIECES

NO LOSSES OF

PRODUCTION

NO CONTAMINATION

BY CNSL ON KERNELS

NO MANUAL LABOUR

REQUIRED

HIGHER

PERCENTAGE

OF WHOLES


Page 22


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AUTOMATIC CASHEW NUT SHELLING-SEPARATION SYSTEM

The automatic shelling line manufactured by OLTREMARE in an integrated system thoroughly

studied and realized to shell and separate calibrated nuts of different sizes (see OLTREMARE

Calibration System). The system processes any size of cashew nuts. After shelling, the

kernels are automatically separated from the shells, ready for drying and peeling section.

Picture 4 Automatic shelling machine


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SEPARATION OF SHELLS FROM KERNELS

CONVEYORS TO THE SEPARATION BENCHES

The S shaped bucket elevators carry the shelled nuts to the separation benches.

The supporting structure is made of electro-welded carbide steel. The chain consists of plastic

buckets suitable for food usage. The buckets are connected to the steel shaft. The conveyor

chain is made of nylon. Both driving and idle heads are aluminium castings, connected by

steel rods. The elevator is equipped at both ends with horizontal pieces to facilitate product

load and discharge. The pieces are made of steel, and are finished with a protection layer of

paint and lacquering coating.

SHELL-KERNEL SEPARATION BENCHES

The shell-kernel separation unit includes:

a) grading sifters

b) shell-nut conveyors

c) pneumatic system for the transportation and recycling of unshelled product

d) percussion cyclones

e) shells aspiration

f) final cleaning of the kernels

Description:

a) Grading sifters

The three-size vibrating separators receive the kernels, and the nuts still not shelled

coming from the shelling and the recycling units. They sort shells and whole nuts from

kernels and small fragments. The movement of the sifters is controlled by levers and

eccentrics, which, in turn, are controlled by a pulley-belt system. At the end of the

separation benches the shells, the kernels, and the residuals fall respectively into the

shell-nut conveyors, the kernel conveyor, the small pieces conveyor. The unit is made

of electro welded steel.

b) Shell-nut conveying unit

The vibrating conveyors and the separation bench make up the main part of the unit.

The shells and the nuts advance through the vibrating channels. At the end of the

line, the heavy parts (nuts and possible shells and kernels still not properly divided up)

fall into the recycling line, while the shells are pneumatically eliminated. The

construction is made of electro-welded shaped steel. The movement is given to the

conveyors through eccentrics.

c) Pneumatic system for the transportation and recycling of unshelled product

The non shelled nuts and the possible shells or kernels still not completely separated

fall into the containers from where they are sucked by the air of the fans and then fed

into the percussion cyclones.


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d) Percussion cyclones

The kernels that are not completely shelled, are pneumatically conveyed to the

cyclones where they bump into a wall so to complete shelling. The kernels and the

shells then fall again into the sifter placed underneath and go back to separation.

e) Aspiration of shells

At the end of the shell-nut conveyors are mounted several aspiration inlets through

which the empty shells are separated from the kernels to be conveyed to the

separation cyclones. The aspiration inlets may be adjusted by means of side

deflectors. This construction is made of electro-welded steel.

f) Final cleaning of the kernels

The kernels are fed from the conveyor belts into an open vibrating channel mounted

on levers and controlled by a tap and an eccentric. The movement is driven by an

electric motor and a pulley-belt transmission system. This unit also controls the

conveyors placed under the aspiration unit. The supporting structure is made of

electro-welded steel.

PNEUMATIC TRANSPORTATION OF SHELLS

The pneumatic transportation system connects the shelling unit to the exterior thus

enabling the automatic discharging of the shells. The first part of this unit includes acid

resistant pipes and PVC bends of medium thickness, collecting the shells falling from the

sifters. The shells are pneumatically conveyed into the separation cyclones connected the

bottom to one another by means of a flange with two discharge radial valves. The body of

these valves is a cast-iron mould housing a star-shaped rotor mounted on a steel shaft. The

valves evacuate the shells outside the factory through the discharge pipes.

DRYING

This operation can be done with a static or continuous dryer.

OLTREMARE cashew kernel continuous dryer consists of one or more standard modules,

assembled in series to attain the desired drying capacity. A final module is placed at the end

of the drying system, similar to the previous ones, but used to cool the kernels.

A single module has the dimensions of the drying room: 2x4 Mts., for total 8 m and it

consists of a kernel feeding hopper over a slotted belt allowing a hot air blast coming from

the bottom of the dryer.

The air is conveyed from the outside by an electric fan and sent to a thermal exchanger

which can be operated electrically or by steam or diathermic oil and it is then conveyed

through the product to be dried upstream the direction of the belt motion.

The parameters on which are based the choices of the regulation system are the following:

Air temperature

Air speed


Page 26

Product stay period inside the dryer.

The regulation devices are the following:

Thermal exchanger temperature regulation device

Adjustment of air inlet and outlet into the drying room

Conveyor run/stop device

Feeding hopper shutter regulation.

An aspirator is placed on the dryer upper hood to ease the hot air flux. In case a

cooling system is used, a hot air recycling device is also foreseen from the cooler to the first

module of the dryer, which can be used as a pre-heater.

The dryer is supplied with slotted belt cleaning device to keep the mesh system

constantly open and ease the air flux.

Picture 5 Continuous dryer


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MECHANICAL PEELING

1 Combined peeling machine

The new OLTREMARE combined mechanical peeling machine represents the latest

development of OLTREMARE technology for peeling cashew kernels.

The basic idea is to combine two mechanical principles in line so to have the maximum

peeling effect in only one pass through the machine.

Such a solution allows a better manipulation of the product reducing breakages and

improving hygienic conditions.

The peeling principles are the following ones:

Rotational drum: the kernels advance into the lower part of the cylinder and the

peeling springs, mounted in packs on an eccentric shaft, touch them gently

while rotating. This action is aimed at fracturing the testa that uniformly covers

the kernel, so to prepare it to the subsequent air compressed action. The

cylinder is made of slotted sheet metal. Sheet-metal slides facilitate the inlet

and outlet of the kernels, while a hopper discharges the detached peels.

From the above action the kernels pass immediately to an air compressed unit

that blows air at a pressure that removes the testa from the kernel.

Adjusting options: inlet flow, distance of springs on kernels, drum rpm, air pressure and belt

speed.

2 - Super-Calibrator

The super-calibrator includes a steel rotor provided with parallel, zinc-plated wires

carrying out a triple-grading of whole kernels and splits. The splits drop onto a conveyor for

split kernels. The whole kernels drop on the sorting bench where this operation is manually

completed. The rotor is mounted on stay rods supported by the main shaft. The rejected parts

pass through the string-rotor and the accepted parts are discharged through the front slide.

The continuous cleaning of the rotor is granted by cylindrical nylon brushes placed over it.

The main shaft is mounted on bearings. It is controlled by a pinion and transmission belt

system. The movement is driven by a reduction gear motor.


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Picture 6 - Combined peeling machine mod. COMBI 300


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OPTICAL SORTING AND GRADING

1 Cashew Kernel colour sorting machine

OLTREMARE is also the brand name of a new series of colour sorting machines suited

to process quite a lot of products, with a special attention to preservation of brittle.

With the aim of obtaining the highest purity and quality standards from products with more

than two colours, in the cashew industry OLTREMARE has successfully installed a double

system on the same machine. This system actually allows the separation among waste,

dessert, scorched and unpeeled kernels without handling the product, thus avoiding costly

breakage.

The OLTREMARE colour sorting machines take advantage of OLTREMARE long years of

experience in cashew processing: the machines are engineered with special devices to

preserve the brittleness of the kernels during the whole colour separation process.

2 OLTREMARE Whole Cashew Kernel Electronic Grading System

The system consists of a feed box (containing the product to be graded) and a vibrator

that conveys the single kernels on a double conveyor belt.

A vision system based on cameras measures each kernel. This information is sent to a

computer which elaborates the data. The kernel is thus classified according to predetermined

class standards (each class represents the cashew kernel international classification grades).

After classification, an air compressed flow separates the kernels which fall into

different boxes according to the grade.

The system is engineered in such a way as to avoid breakage.

This system is in condition to classify a huge quantity of kernels achieving a high-level

precision grading that is actually far more precise than manual grading. Power consumption is

very low. No labour is required, thus avoiding unhygienic handling of the kernels.


Page 30

Picture 7 Optical-electronic color sorting machine LUX series


Page 31

Picture 8 Grading process flow chart

Picture 9 Automatic grading machine for cashew kernels FALKO series


Page 32

PACKING

1 Characteristics

Strong and compact construction in stainless steel (also available in painted carbon steel)

Vertical operation

Possibility to pack different sizes of packages from 10 to 35 kg

Semiautomatic machine in the sense that the pre-filled plastic moulds have to be placed

manually in the machine, but the cycle is automatically operated and controlled

Digital program control panel and visualization of processing parameters

Electronic card with microprocessor to control the working cycle

Possibility to program and memorize up to 10 working cycles according to the different

packing needs

Possibility to pack with different bag materials (suitable to retain the vacuum) thanks to

the sealing bar adjustable parameters

Sensor for pressure control inside the vacuum chamber

Double sealing bar

Sealing electronic control

Vacuum pump capacity = from 100 to 180 m/h

Installed power: from 2.2 to 5 KW electric motor

2 Working parameters

Setting of KPA residual pressure after vacuum cycle

Setting of KPA pressure after gas injection

Setting of rest time between gas injection and sealing to homogenize gas distribution

inside the package

Setting of sealing bar temperature

Setting of sealing time


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Picture 10 Vacuum packing machine OLPACK series

Picture 11 50 lb vacuum pack of cashew kernels


Page 34

OLTREMARE S.r.l

Via dellIndustria, 17/19 Zona Ind. Bargellino 40012 CALDERARA DI RENO (BO)

Tel.: +39-051-2988311

Fax: +39-051-2988333

E-mail: [email protected]

WEB: www.oltremare.biz

the world of cashew november 2011

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