Nearly one-third of all food in the U.S. goes uneaten each year, according to ReFED, and fresh produce accounts for a significant share of that loss. For fresh-cut processors, this reality shows up every day on the line in lost yield, inconsistent product and the constant pressure to do more with fewer resources.
Because fresh produce is inherently variable in size, shape and texture, operations without the right cutting approach quickly suffer from off-spec results, product damage and significant yield loss. Furthermore, mounting labor constraints mean equipment must be simple to set up, run and maintain to minimize human error — a leading cause of product waste.
While sustainability is often discussed in broad, corporate terms, the most meaningful improvements happen right on the factory floor, says Paul Krechel, executive vice president of North America for Fam Stumabo USA. High-capacity, high-precision cutting solutions — such as Fam Stumabo ‘s Volantis and Yuran systems — are designed to bridge this gap, helping processors optimize throughput and stabilize repeatability without sacrificing quality.
Ultimately, smarter cutting is about building better, more resilient operations. Krechel dives deeper into the mechanics of precision cutting, explaining how managing natural variability, de-skilling machinery and capturing “invisible” losses can fundamentally transform a processor’s bottom line.
The Packer: When fresh-cut processors look at their daily waste, what are the most common, yet easily overlooked areas where yield is being lost during the cutting stage? How can they better measure this invisible loss?
Krechel: When processors think about waste, they often focus on what they can clearly see at the end of the line. However, some of the most significant yield losses are less visible and occur throughout the cutting process itself. Common examples include excessive trimming, fines generation, product damage and pieces that do not meet specifications and therefore need to be reworked or discarded. Individually, these losses may appear small, but across high production volumes, they can have a significant impact on both yield and profitability.
To better understand where yield is being lost, processors should look beyond finished product output and monitor factors such as how fines are generated, which could be due to knife quality. Even small improvements in cutting precision can help reduce waste and improve product recovery over time.
Because no two apples or potatoes are shaped exactly alike, what specific mechanical features or technologies allow modern cutting equipment to adapt to this natural variability without slowing down the line?
Natural variability is one of the biggest challenges in food processing. Every fruit or vegetable is different, and maintaining consistent results while processing high volumes requires more than simply increasing cutting speed.
Modern cutting equipment is designed to guide and stabilize the product throughout the cutting process. Features such as optimized feeding systems, precise product positioning and application-specific cutting technologies help ensure products enter the cutting area in a controlled, consistent manner.
Blade design also plays an important role. When combined with proper product handling, it helps deliver more uniform cuts, reduce product damage and maintain throughput even when raw materials vary significantly in size, shape or texture. As a result, processors can achieve both consistency and efficiency without sacrificing productivity.
The goal is not to force the product through the machine but to manage its interaction with the cutting system for best results.
With fewer experienced operators available in processing plants, how are equipment manufacturers designing machines to be foolproof or easier to operate? What does ease of maintenance actually look like on a high-speed line?
Labor challenges are affecting virtually every segment of the food processing industry. As experienced operators become harder to find, equipment manufacturers are placing greater emphasis on simplicity, consistency and ease of operation.
The goal is not necessarily to make machines foolproof but to design systems that help operators achieve consistent results with less training and less risk of error. This includes intuitive machine setups, simplified adjustments, easier product changeovers and cutting systems that deliver reliable performance from the first cut.
Ease of maintenance is equally important. On a high-speed production line, every minute of downtime matters. Equipment that provides easy access for cleaning, blade changes and routine maintenance helps reduce downtime while supporting food safety requirements. Ultimately, processors are looking for equipment that is easier to operate and maintain and that delivers consistent performance day after day.
Now more so than ever, we see an increase in installations of cutting equipment in smaller operations such as commissary kitchens and central kitchens. This is directly related to the lack of personnel.
Sustainability is often treated as a broad corporate buzzword. In practical, day-to-day terms on the factory floor, how does reducing waste by even a fraction of a percent impact a processor’s bottom line and environmental footprint?
One of the most practical ways to think about sustainability is through resource efficiency. Every piece of product that is unnecessarily lost during processing represents wasted raw material, as well as the water, energy, labor and transportation resources invested in producing it.
This is why even small improvements in yield can have a meaningful impact. A 5% improvement in yield may seem small, but for a processor handling thousands of pounds of product per day, it can translate into a substantial increase in recovered product over the course of a year. Recovering more usable product from the same amount of raw material helps improve profitability while reducing overall waste.
In many cases, operational efficiency and sustainability go hand in hand. When processors reduce waste, improve product recovery and optimize their processes, they are not only improving their bottom line, but they are also making better use of the resources that enter the facility every day.
Traditionally, there can be a trade-off between speed/capacity and precision. How has cutting technology evolved to ensure that processing larger volumes of food doesn’t automatically mean sacrificing product consistency?
Historically, processors often had to balance throughput and cut quality. As production speeds increased, maintaining consistency became more challenging, particularly when working with natural products that vary in size, shape and texture.
Today, cutting technology has evolved significantly. Modern equipment combines improved product handling, more precise feeding systems, optimized cutting principles and advanced blade designs to maintain consistent cutting performance even at high production volumes. Rather than simply increasing speed, manufacturers focus on controlling how the product moves through the cutting process and interacts with the cutting system.
As a result, processors no longer have to choose between capacity and consistency. High-capacity cutting solutions can deliver both, helping processors maximize throughput while maintaining product quality and reducing waste.
Processors should not have to choose between throughput and consistency.
