Case Study
El Dorado Almonds Achieved Complete, End-to-End Automation of their Sizing Process with Borde Inspect
The Challenge
El Dorado Almonds needed a more efficient and accurate way to manage quality control on their sizing line. Their previous process relied on manual QC labor, probes, and 500-gram samples, which offered only a limited snapshot of true product quality. This created challenges in maintaining consistency across all sizer lanes, reducing rework and processing times for work orders, identifying USDA-defined defects with precision, meeting exact bin specifications, and seamlessly integrating quality data into their inventory management system.
The Solution
In partnership with El Dorado Almonds, Borde installed Borde Inspect Systems on every lane of their sizer, fully automating the in-line, AI-powered quality control process. The system activates automatically when a new bin is placed on the scale and tared. As product begins to flow through each sizer gate, Borde captures and analyzes every kernel in real time, replacing probes and 500-gram samples with full-kernel inspection. Each kernel is classified by Borde’s AI according to USDA defect categories, giving El Dorado a comprehensive and highly accurate view of the product moving through their line. Plant operators can monitor product flow and real-time report generation through Borde’s web-based interface from anywhere on site. When the bin reaches its 2,250-pound target weight, the system shuts off, finalizes the inspection, writes the QC data directly into El Dorado’s inventory management system, and prints a unique bin tag with a summary report by both piece count and percentage by weight. By moving from manual sampling to 100% inspection, El Dorado Almonds has eliminated the need for QC labor on the sizing line, significantly reduced rework and processing times, and gained the ability to pull bins that meet exact specifications. This collaboration showcases the transformative benefits of AI-driven automation for tree nut processors across California.
The Benefits
- Complete automation and higher accuracy: 100% kernel inspection eliminates manual QC labor, replaces probe-based sampling, and provides a far more representative and precise view of product quality.
- Greater efficiency and reduced rework: Real-time, full-line inspection significantly cuts rework, shortens processing times, and enables operators to confidently pull bins that meet exact specifications.
- Seamless data flow and real-time visibility: Automated report generation, instant integration with inventory systems, and live monitoring through Borde’s web interface streamline operations across the entire plant.
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