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The quality of hazelnuts, sized and cracked by different systems was compared in a commercial processing plant by determining the percentages of nuts that were damaged, broken, left-in the-shell, cracked, unbroken, recyclable, or undamaged. Hazelnuts larger than 16 mm diameter had different cracking behaviour, as compared with smaller ones. In experiments with a traditional Turkish cylindrical sizer and stone cracker combination, 3·3 % (standard error 2·7%) damaged nuts were produced when the diameter of the nuts were larger than 16 mm, and 15·9% (7·5%) damaged nuts were produced when the diameter of the nuts was less than 16 mm. The average of the damaged nuts was around 16% with all the conical cracker combinations. Hidden-damage (apparently good appearance from the outside, but darker colour and oily appearance inside) was 38% (4·0%) for the cylindrical sizer/stone cracker …