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Leafy greens processing

Reliable and efficient leafy greens processing

At the core of successful leafy green processing is meticulous handling, stringent food safety, and precise process control. The diversity of leafy greens adds another layer of complexity, as each type has unique requirements. For example, iceberg lettuce demands precise core removal, while spinach requires particularly gentle handling and careful thermal control throughout the process.

Sormac equipment is purpose-engineered and fully tailored to your specific crop and production conditions, ensuring that the right processing technology delivers an immediate impact on quality, yield, and shelf life.

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Leading in leafy green processing

Sormac leverages over 35 years of expertise in leafy green processing, supporting processors and growers in designing and optimizing their production processes. Through continuous innovation and close collaboration with our customers, we deliver industry-leading solutions that integrate advanced technology, hygienic design and microbiological expertise. The result is a safe, efficient, and future-proof production, supported by machinery that is both reliable and built to last.

The right processing for every crop

Our portfolio covers all processing steps necessary for the production of fresh-cut leafy vegetables and salads. Lines can be fully adapted to the crop type, production capacity, and desired end result – including considerations such as high volume production, flexibility for fast changeovers, limited space, or third party equipment integration.

Our solutions are suitable for the fresh processing of a wide range of leafy greens, including:

  • Head lettuce such as iceberg and butterhead;
  • Loose-leaf varieties (open head) including oak leaf, frisée, lolo rosso/bionda, and endive;
  • Elongated (romaine) lettuces such as romaine and little gem;
  • Delicate, loose-leaf greens without a core including spinach, red chard, and baby leaf mixes;
  • CEA-grown leafy greens, cultivated under glass in Controlled Environment Agriculture (CEA)

Coring

Maximum yield in iceberg lettuce coring

The Sormac OptiCor OC is an advanced lettuce coring equipment designed to achieve more than 95% yield. The process consists of four steps: precise camera-guided positioning, individual core measurement, automatic calculation of the coring depth, and precision coring from the underside. Optionally, the lettuce can be cut into two or four segments. The additional OCS infeed system allows automatic supply and singulation of the iceberg heads, making the production process even more automated.

The hygienic design and 100% waste separation ensure a safe and efficient process. Thanks to this unique coring method, the OptiCor is the solution of choice for the fresh produce market, where quality, precision, and food safety are essential.

Discover the innovative Lettuce corer OptiCor

OptiCor OC iceberg lettuce decorer - Sormac
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Washing

Gentle washing of (delicate) leafy greens

As leafy greens such as baby leaf, spinach, and red chard are highly delicate, achieving the right balance between thorough cleaning and gentle product handling is essential. During washing, dirt, sand, and bacterial residues are carefully removed. The Sormac washers create controlled water flows and turbulence that reach every leaf surface without damaging the product. Discover our portfolio for washing leafy greens:

  • Salad washers PULSTAR-range available in four versions, the washers are equipped with adjustable air injection system and are ideal for (delicate) leafy greens;
  • Spiral washers SW-50 series and SW-80 feature adjustable water flow and are suitable for washing cut and uncut vegetables and fruit, both floating or sinking;
  • Wash flume WF a water transport channel equipped with an air injection system.

Drying up to 0% residual moisture content

Residual (or surface) moisture content (RMC) is the water that remains on and between the leaves after washing and drying. High residual moisture can promote microbial growth and subsequently reduce shelf life. That is why Sormac develops drying techniques that remove residual moisture effectively, while handling the leafy greens gently to preserve product integrity.

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Drying

Optimal drying of leafy greens 

Sormac offers a complete range of drying equipment for leafy greens, including horizontal and vertical mechanical centrifuges as well as thermal dryers.

Our vertical systems are suitable for both leafy greens and firm fresh-cut vegetables and are available in manual (MC) and automatic (FC) versions.

Our horizontal centrifuges SC/NextGen are designed for all types of leafy greens and provide an extremely careful, product-friendly treatment. Thanks to the unique infeed system, a thin layer of product is applied to the drum, allowing even the most delicate leafy greens to be dried safely and effectively using mechanical spinning.

For highly delicate leafy greens, the LDT-series air-drying tunnels provide a thermal drying solution capable of reducing residual moisture (RM) to 0%.

Read more about the differences between mechanical and thermal drying

Sormac is here to assist you

Discover the right washing and drying method for your product. Request a consultation with one of our specialists.

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Mixing

Maintain control over your salad mixes

During the production of salad mixes, precise dosing and gentle mixing are essential. That is how controlled supply prevents leaves from breaking or being compressed. While recipe-driven dosing allows easy switching between formulations, whether simple two-ingredient mixes or complex recipes with multiple components.

Our Automatic recipe conveyor RBA and Recipe conveyor RB supply mixes - or single ingredients - onto the line in a controlled manner. To achieve a homogeneous end product, various natural transitions within the line can be utilized.

Additionally, our washers - when this processing step is required - are well-suited for gently combining components. If this step is not necessary, specialized mixing drums provide an effective alternative, ensuring even distribution of all components and, consequently, consistent product quality.

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Processing lines

Leafy greens processing from start to finish

Our processing lines for leafy greens combine precision, hygiene, and advanced automation to ensure that every type of crop is handled safely and consistently. Whether it’s iceberg lettuce, oak leaf lettuce, field-grown spinach, or CEA-grown leafy greens from controlled environment, our lines deliver predictable production, minimal manual handling, and a high-quality end product.

Below are some examples of our leafy green processing lines.

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Baby leaf washing and drying line

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Iceberg lettuce washing and drying line

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Vegetable processing line

Controlled Environment Agriculture (CEA) Applications

Processing leafy greens grown in CEA environments requires a specialized approach. For example, washing may not always be necessary, but it is important that the product is cooled back to packaging temperature.

Would you like more information about our solutions for the CEA industry? Contact our specialists - they will be happy to explain the possibilities.

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Knowledge partners with an in-house laboratory

In 2016, Sormac strengthened its expertise with the establishment of its own Microbiological Laboratory. This lab supports both customers and Sormac’s R&D and engineering teams in the areas of hygiene, microbiology, and process optimization.

For both Sormac and customers, the lab provides valuable insights from fresh produce processing. By performing targeted analyses at critical points in the process, it helps identify exactly where and how product damage occurs and where optimizations are possible. This allows improvements to be applied in a focused manner, further enhancing overall product quality.

Discover more at our knowledge center

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Hygienic machine design as a foundation for food safety

Hygienic machine design plays a crucial role in ensuring food safety during the processing of leafy greens. The design is based on the principle of easy and thorough cleanability, enabling effective disinfection. This minimizes microbiological risks and results in a hygienically safe machine.

At Sormac, this principle is central to all the machines we design. Examples include:

  • Easy to clean, smooth surfaces that reduce the risk of bacterial buildup.
  • Water-draining frame with sloped surfaces to prevent water retention.
  • Open frame structure.
  • Easy access for cleaning through large, wide-opening doors.
  • Hygienic zones where mechanical components are located below the product flow.
  • Foldable fans on dewatering and transport conveyors.

Automation for more control of your process

Sormac automates complete processing lines, providing maximum control and operational reliability. Both the machines and the control systems are developed and built in-house, allowing us to offer a fully integrated total solution to our customers. Our control systems are available with both Allen-Bradley and Siemens platforms and enable seamless integration of all machines in the line, including third-party equipment. All lines are cloud-ready via IXON, enabling remote access, remote support, and performance dashboards.

The result: full line control at the touch of a button, better oversight of your process, higher line availability, and a future-proof installation that grows as your production grows.

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Remote Service

Our service specialists can log in to your machines remotely via a secure internet connection. This allows us to provide fast support for operation, settings, and optimizing your leafy greens processing workflow. Would you like to learn more about our service solutions?

Go to service

Frequently asked questions about leafy greens processing

Residual moisture content (RMC) is the water that remains on and between the leaves after washing and drying. It can increases the risk of bacterial growth which reduces the shelf life. To measure the residual moisture percentage, Sormac has developed a dedicated working method. Contact us to learn more about this method.

As leafy greens are very delicate, achieving the right balance between thorough cleaning and gentle product handling is essential. Sormac washers support various techniques to achieve this balance. In addition, Sormac has conducted laboratory research on the effective removal of soil particles during the washing of leafy greens. Read more about this research in our knowledge center.

Mechanical drying removes excess surface water from leafy greens by means of centrifugal force. Thermal drying, on the other hand, uses (warm) air to evaporate moisture. Learn more about the differences in our knowledge article on the various drying techniques.

Yes. Depending on the situation, we can configure the line and controls to include both Sormac machines and third-party equipment. Contact us to learn more about the possibilities.

Sormac is ready for you

Would you like to achieve more yield from your leafy vegetable processing, with less manual work and a stable process? We are happy to think along with you. 

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