International Seed and Pulse Processors

Pulse Processing

Dunns have processed dried pulses for over 30 years and specialise in adding value to a variety of different products

Originally designed to add diversity to its business, Dunns’ largest processed tonnage and turnover is now dried pulses.

With experienced staff, hi-tech machinery and BRC accreditation for Food Safety, Legality & Quality, Dunns provide a quality of service and product that is accepted worldwide for a wide range of uses.

Investing in state-of-the-art technology

In 2009, Dunns made the executive decision to upgrade its production facility and over the next year, invested over £2.5 million in a state-of-the art production line.

This line concentrated on efficient processing, increasing quality and output whilst reducing labour.

Dunns analysed previous complaint trends and highlighted that stones have previously been an issue within the product, therefore a decision was made to ensure the risk of stone contamination within the finished product was brought to an absolute minimum. Therefore Dunns installed a double de-stoning system, coupled with laser colour sorting and X-Ray detection to ensure the product would meet every customer’s specification.

The latest technology was coupled with well-practiced techniques; these included recycling of product for re-grading to reduce losses and the installation of a TOMRA IXUS Bulk X-Ray sorter- the largest X-Ray machine in dried pulse processing in the UK.

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Bulk X-Ray sorter

Dunns chose an X-Ray sorter and Laser Sorter over the more traditional camera technology principally due to the dusty environment in which it is situated. As the camera technology requires a lens, dust can form a film over the lens causing deterioration in the sorting ability of the machine. However because both X-Ray and laser doesn’t have a lens this problem is avoided, leading to much more accurate and consistent sorting results.

The laser sorter is also very efficient at separating product by density and texture, this ensures contaminants such as stones / metal / glass are highlighted and removed.

Decorting / Splitting Process

Dunns are committed to adding further value to finished goods; this can be achieved by decorticating (skinning) and splitting dried pulses.

Dunns have sophisticated skinning machines called “decorticators” installed in the production line, these are a series of abrasive stones that physically rub the skins off the pulse. The skins are aspirated away from the skinned / decorticated product and are conveyed into a bulk trailer for animal feed.

After skinning, the peas can either be split or polished (or both) depending on the customer’s requirement.

Splitting pulses is achieved by pushing the product through oscillating knives, this causes the products to split down the cotyledon (central scar) and split into two even halves.

Polishing of the product with inert talcum powder helps gives the product a much more aesthetically pleasing appearance; it also reduces the levels of dust and flour within the product to a satisfactory level, as dust can cause issues with heat sealed packaging.

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Packing

Dunns have a fantastic packing facility that allows product to be packed in a range of sizes from 10kgs to 2000kgs.

Our packing facility includes both a bulk bagging line and an automatic bag placer and palletiser. The bulk bagging system can bag either straights or blends using an automatic weigher that blends the product accurately prior to bagging, this is ideal for blending whole and decorticated product.

We can bag any size between 10kgs and 25kgs on the automatic palletiser, this machinery has the facility to bag up to 1000 bags per hour, which has considerably increased the outturn capacity.

Traceability

Dunns’ traceability is a simple and effective system, giving customer confidence that any product processed at Dunns will be of the highest quality and can be traced from field to fork.

A unique, sequential lot number is allocated to each product and farm at the point of origination into site. This lot number follows the product from Intake, through production and onto each individual bag. This enables any customer to report the lot number to us on supply, this keeps all products traceable, including date of production, quality on arrival, quality after processing and previous and following commodities processed. Our traceability system falls in to line with current TASCC and Soil Association standards and is rigorously controlled by our HACCP plan.

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Some uses include

  • Mushy Peas
  • Wasabi Peas
  • Soups & Sauces
  • Ethnic Flours
  • Supermarket retail packs
  • Catering

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Registered Office:
Winters Lane, Long Sutton,
Spalding Lincolnshire PE12 9BE