Project Overview
A potato processing plant in the United Kingdom struggled to remove soil trapped in potato eyes and grooves using straight-trim rollers. Higher spray pressure and longer washing times failed to solve the problem, leaving operators to remove rejected potatoes manually. Fortex Brush developed a custom wavy-profile vegetable cleaning brush with a 9 mm peak-to-valley offset, allowing the bristles to reach recessed areas that conventional rollers and water sprays often miss.
The solution retained the existing shaft positions and roller stations without modifying the drive train, frame, or spray bar. The table below summarises the agreed project specifications.
| BASIC INFORMATION | PROJECT DETAILS |
|---|---|
| Customer Industry | Potato and root vegetable processing |
| Market | United Kingdom |
| Custom Product | Wavy-profile nylon bristle cylinder roller brush |
| Main Specifications | 138 mm finished brush OD; 80 mm core tube OD; 30 mm bore; 9 mm wave amplitude; 75 mm peak pitch |
| Bristle Configuration | Food-grade nylon, white, wave trim |
| Roller Length | Matched station by station to the existing line layout |
| Sampling | Straight-trim sample first, then wavy profile after line trial |
| Estimated Production Time | Within 20 days |
| Actual Production Time | 8 days |
| Shipping | Sea freight |
| Project Process | Specification drawing, dimension confirmation, sampling, line trial, profile revision, production, photo inspection, shipment |
From Drawing to Order
The customer supplied machine measurements rather than drawings, including shaft diameters, roller centre distances, and clearance under the spray bar. Fortex prepared a specification drawing from these measurements and returned it for approval against the actual line layout.
Four dimensions were fixed: the 30 mm bore matched the drive shaft, the 80 mm core tube provided the winding base, the 138 mm finished outer diameter determined bristle reach, and roller lengths matched individual stations. Other dimensions remained adjustable.
Two values defined the brush profile. The 9 mm wave amplitude set the height difference between each crest and trough, creating a working height of approximately 24.5–33.5 mm above the core. The 75 mm peak pitch controlled wave spacing. The finished wound cylinder brush therefore carried approximately thirteen crests per metre.
Our Custom Solution
The wavy face is more than a cosmetic change. It improves contact with irregular potato surfaces, allowing the brush to reach recessed areas while distributing cleaning pressure more evenly.
1. Drawing Review and Line Interface Check
Since the existing drive system could not be modified, Fortex first confirmed the 30 mm bore, 80 mm core tube, and 138 mm finished diameter against the machine interface. Roller lengths were matched to individual stations, ensuring proper shaft fit and sufficient clearance from neighbouring rollers and the spray bar before production.
2. Wave Profile Geometry and How It Cleans Every Eye
The wavy profile creates alternating high and low contact points as the roller rotates. Its crests reach into potato eyes and stem cavities, removing trapped soil that straight-trim rollers often miss.
As the bristles bend and recover, they help move and tumble tubers forward. This allows different surface areas to contact the brush, achieving more complete 360° cleaning without an additional turning device. The distributed contact also reduces concentrated pressure on individual bristles, helping clean potato skins without excessive scuffing. Larger wave amplitudes can also loosen skin before peeling.
3. Material and Core Specification for Wet Food Duty
For this wet-processing nylon cylinder brush, food-grade nylon was selected for its wet stiffness and bending recovery, helping maintain the 9 mm wave profile during continuous operation. Filament diameter was set at 0.40–0.60 mm to balance cavity access and cleaning strength. The food-grade polymer core was sealed at both ends, with the bore machined to match the drive shaft. Material suitability for food contact was checked before production.
4. Production Control and Pre-Shipment Inspection
Production followed the approved drawing, with winding tension and wave geometry checked throughout manufacturing. Fortex verified the 9 mm wave amplitude, 75 mm peak pitch, finished diameter, and bore fit. Each roller was labelled by station number and photographed before packing to document its dimensions and finished brush profile.
Delivery & Results: Efficient Production and Reliable Delivery
A retrofit depends on accurate installation, so Fortex focused on dimensional checks and protective packaging before dispatch.
Dimensional Verification Before Dispatch
Each roller was checked against the approved drawing, including bore, core diameter, finished OD, crest height and 75 mm pitch. Wave phase was also recorded to ensure adjacent rollers had offset crests and troughs, reducing untreated areas across the potato bed and improving cleaning coverage.
Packaging and Sea Freight to the United Kingdom
For sea freight, each roller was supported along its core, with bristles protected from compression and moisture during transit. This prevented permanent deformation that could reduce the crests’ ability to reach potato eyes. Beyond the washing stage, a conveyor belt cleaning brush can also help remove residual soil from discharge belts, providing another practical option for maintaining cleanliness across the processing line.
Our Service & Manufacturing Capabilities
- Drawing Review: specifications built from the machine as it stands, with fixed and adjustable dimensions separated before production.
- Sampling and Line Trial: a first sample run on the customer’s own produce, with feedback on contact, tumbling and skin condition translated into a revised profile.
- Wavy Profile Customization: amplitude and pitch set around tuber size and soiling level rather than a catalogue value.
- Material and Core Customization: filament type, diameter, colour, core material, bore and trim configured to the wash water and the shaft.
- Production Visibility: photographs of finished parts before dispatch, with every dimension recorded against the drawing.
- Replacement Guidance: trim wear of about one third of original height is the practical point to re-order, which on most root vegetable lines falls between six and twelve months of running.
Custom Wavy Vegetable Cleaning Brush Solutions & Inquiry
The same wavy geometry suits other produce, including carrots, ginger, taro, sweet potatoes and lotus roots, where recessed areas trap soil. It also works for firm fruit polishing with a smaller amplitude. Available materials include nylon, polypropylene, polyester and blended filaments. Brush formats include wound rollers, sleeved cylinder cleaning brushes, and spiral sets for continuous-feed applications.
For a quotation, provide the produce type, roller quantity and spacing, shaft diameter, finished outer diameter, roller length, filament material and diameter, washing conditions, and destination port. If dimensions are uncertain, describe the cleaning problem instead. Fortex can recommend a suitable wave profile and prepare a specification drawing from machine measurements for approval before production.
