In one of our most technically advanced projects, TMS was commissioned by Chipsy (PepsiCo) in October City to design and manufacture a custom potato reception conveyor system. The challenge was to seamlessly integrate with a set of imported conveyors from Germany, each measuring 30 meters in total length, while manufacturing the remaining conveyors locally to identical specifications.

TMS engineers were provided with a sample German conveyor on-site, which allowed us to reverse-engineer the exact dimensions, tolerances, and material specifications. We then developed precise shop drawings and 3D models to ensure that the locally manufactured conveyors would perfectly match the imported system. This project demanded strict adherence to PepsiCo’s international quality standards, requiring accuracy in both mechanical fabrication and automated control systems.

The completed conveyor line had a total length of 30 meters, divided into three main sections:

Section 1: A 12-meter long primary receiving conveyor.

Sections 2 & 3: Two additional conveyors, each 6 meters long, extending the line to the full 30 meters.

Each conveyor was designed with a belt width of 700 mm, suitable for handling bulk raw potatoes, and an inclined profile that transitioned from 1.6 meters in height down to 0.7 meters. This gradient allowed for smooth transfer of potatoes from unloading trucks/containers to the downstream washing station.

The belts were manufactured from food-grade rubber reinforced with polyester fabric layers for strength, and shaped into a “V” profile through angled support rollers. This V-shaped belt profile served two functions:

Preventing product spillage by cradling the potatoes during transfer.

Increasing throughput capacity by allowing the conveyor to hold a larger volume of product per meter.

To ensure hygienic operation and long service life, the conveyor frame was built from 304 stainless steel, with welded joints ground smooth to meet food safety and CIP (Clean-in-Place) requirements. The belt understructure featured idler rollers mounted at calculated angles, giving precise V-formation and reducing belt stress.

The system was powered by reliable gear-motor drive units with torque limiters to protect the belt in case of overload. Advanced control logic was integrated:

Limit switches and proximity sensors monitored potato flow along the line.

Automated start/stop control activated the conveyors only when product was present, reducing unnecessary energy use.

The system was designed to synchronize with the washing station, ensuring smooth handover without bottlenecks.

TMS faced challenges in fabricating components that could withstand both continuous high-volume operation and the abrasive nature of raw potatoes (soil, grit, and moisture). To address this, we used abrasion-resistant rubber for the belt cover and incorporated easy-to-access tensioning systems for maintenance.

The entire project was executed within tight deadlines, with manufacturing completed in record time while maintaining international standards. After installation, the conveyors were tested under full-load conditions, successfully transporting bulk potatoes from trucks directly into the washing and peeling line without product loss.

Since commissioning, the system has operated smoothly with only routine quarterly maintenance and belt cleaning, earning high praise from the client. This project demonstrated TMS’s capability to deliver complex, high-precision, food-industry conveyor solutions that integrate seamlessly with global OEM equipment — at a fraction of the import cost.