avoid pitfalls when planning for your next conveyor · 2019-09-25 · qc conveyors • 12 ......
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eHANDBOOK
Avoid Pitfalls When Planning for Your Next Conveyor
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TABLE OF CONTENTSConveying Cleanliness 5
The right materials and design can make it possible for a conveying system, of any kind, to
achieve reliable sanitation.
Factors to Consider When Sourcing Pneumatic Conveying Systems
for Powders That Are Difficult to Move 13
Food Grade Conveyor Systems: What You Should Know Before You Buy 16
Evolution of Conveyors in Food Processing 19
AD INDEXTuthill • www.tuthill.com 2
Citgo • www.clarionlubricants.com 4
Cablevey • www.cablevey.com 6
Rexnord • www2.rexnord.com/foodconveying 8
Rice Lake • www.ricelake.com 10
QC Conveyors • www.qcconveyors.com 12
Vac-U-Max • www.vac-u-max.com 15
Dynamic Conveyor • www.dynamicconveyor.com 18
Multi-Conveyor LLC • www.multi-conveyor.com 21
eHANDBOOK: Conveying / Sorting / Powder Bulk Handling 3
www.FoodProcessing.com
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A speck of food residue on a con-
veyor is a potential time bomb.
Any product accumulation, no
matter how small, that allows microorgan-
isms to fester on a conveyor can rapidly
taint an entire production shift. Now that
DNA mapping can quickly trace microbial
contamination back to its source, the lia-
bility of a recall or worse that can deal a
lasting hit to a processor’s reputation is
greater than ever. Recent changes in the
law put even more pressure on processors
to pay attention to sanitation.
“The FDA Food Safety Modernization Act
(FSMA) is transforming food companies
by shifting the focus from responding to
foodborne illness and foreign material con-
tamination to preventing it,” says Soren
Pedersen, food global team leader for belt
supplier Intralox (www.intralox.com).
That’s why cleanability is among the highest
priorities that food processors have for con-
veyors. They’re long, complex systems that
move lots of product as quickly as possible.
Contamination has the potential to get
out of control before anyone realizes that
something is wrong.
There are, of course, a wide variety of
conveyors, and a lot of different ways of
keeping them clean – and of designing
them to be kept clean. Design aspects for
cleanliness include the nature of welds and
fasteners, the ease with which sections can
be disassembled, the finish of the metal,
the materials used in the belt or chain, the
nature of the power transmission compo-
nents, and more.
STEELY RESOLVE Perhaps the most basic specification for
cleanability in a conveyor is the use of
stainless steel for most of its construction.
Most food-grade conveyors marketed
today – at least, those intended for direct
product contact – are stainless steel,
which resists both microbial growth and
corrosion better than coated mild steel.
“Sanitary conveyor systems are stain-
less steel constructed, premium welded
Conveying CleanlinessThe right materials and design can make it possible for a conveying system, of any kind, to achieve reliable sanitation.
By Pan Demetrakakes, Senior Editor
eHANDBOOK: Conveying / Sorting / Powder Bulk Handling 5
www.FoodProcessing.com
(641) 673-8451www.cablevey.com
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and built specifically as dictated by san-
itation or food safety requirements,”
says Cheryl Miller, marketing director for
Multi-Conveyor (www.multi-conveyor.
com). “Any food conveyor manufacturer
has to keenly understand the need for
effective, easy-to-clean, CIP/COP [clean-in-
place/clean-out-of-place] and washdown
equipment.”
Another aspect to pay attention to is the
steel’s finishing method. When it comes
to corrosion, which increases in risk with
harsher washdown chemicals, grade 316
stainless performs better than 304. Accord-
ing to Jim Ruff, vice president of process
systems and integrated solutions at Key
Technology (www.key.net), a rotary polish
finish will leave the surface with a smoother
surface and inhibit microbial attachment
better than the alternative 2B mill finish. At
a minimum, he says, stainless steel and a
rotary polish should be considered within a
conveyor’s product contact zones.
However, when it comes to sanitation, it’s not
enough for a conveyor merely to consist of
stainless steel, says Stacy Johnson, director of
marketing and strategic planning for Dorner
Manufacturing (www.dornerconveyors.com).
“Just because a conveyor is stainless steel
doesn’t necessarily mean it’s sanitary,”
Johnson says. “A basic stainless-steel con-
veyor can be washed throughout the day
as needed, depending on how it is built, but
it’s not necessarily sanitized. That’s because
sanitizing or cleaning a conveyor involves
an entirely different process than simply
washing it down, and much of achieving a
sanitized conveyor depends on the way it
was initially designed.”
ROUNDING OFF The design for a sanitary conveyor
should involve as few points as possible
for product residue to accumulate, with
welded, rounded frames and minimal
fasteners in the food zones. Examples
include Dorner’s AquaPruf and AquaGard
conveyor systems and the DynaClean
sanitary conveyor from Dynamic
Conveyor (www.dynamicconveyor.com).
The DynaClean features a motor and
controls that can be removed without
tools, a belt that can be removed with
one lacing rod and retaining walls that
also can be removed without tools.
The biggest hot spot for sanitation in a con-
veyor is the product-contact surface – the
belt, pan, or tube that actually carries the
product. This is where it’s most important
that finish and choice of material match the
application. That means not only conveying
the product efficiently, but being compatible
with whatever sanitation method is required.
Typical belt materials, according to Key
Technology’s Ruff, are fabric, modular
plastic and solid plastic. Fabric belts are
liable to fray, presenting a significant
www.FoodProcessing.com
eHANDBOOK: Conveying / Sorting / Powder Bulk Handling 7
Increased Uptime and Less Downtime Depends on the Right Conveyor Belt
Rexnord’s full suite of food safe metal
and plastic modular belts give you
an end-to-end solution for your food
processing line. Our belting designs
have features that enable efficient
sanitation, installation and maintenance,
reducing downtime and optimizing
your total cost of ownership.
Learn more at www2.Rexnord.com/FoodConveying
sanitation problem, unless the edges are
encapsulated. Modular plastic is popular
for products with high water activity, such
as meat and poultry, where moisture needs
to drain away. But optimal from a sanitary
standpoint, Ruff says, is a seamless positive
drive urethane belt, which both eliminates
crevices and is relatively easy to disengage
for cleaning.
Other types of conveyors don’t use belts at
all. For instance, Heat and Control (www.
heatandcontrol.com) uses a variety of fin-
ishes for its Fastback horizontal-motion
conveyors, which convey fragile product
by sliding back and forth. Options include
an electropolish finish for delicate wrapped
candy, a rigidized one for frozen products
and a Tivar lining for products whose high
sugar content is liable to build up in the
conveyor bed.
The means of powering the conveyor
are just as important, from the stand-
point of hygiene, as the product-contact
surfaces. The nature and location of the
motors and their connections to the belt
have to be configured correctly to maxi-
mize cleanability.
The basic options for power transmission
are: standalone motors located along (usu-
ally beneath) the belt and connected to
gearboxes; gearmotors, which combine
motors and gearboxes in one unit, usually
enclosed; and drum motors, which are more
powerful motors, located at the end of the
belt loop, that pull the entire belt length.
Each has practical advantages. Separate
motors and gearboxes are usually cheaper,
because they’re standardized across a vari-
ety of industrial uses. Gearmotors are often
easier to specify and install, while drum
motors tend to be more energy-efficient.
But when it comes to sanitation, gear-
motors and drum motors have a distinct
advantage: Being enclosed makes them
stand up to washdowns better.
“This conventional arrangement of driv-
ing conveyor belts in the industry creates
numerous gaps and crevices for food
byproduct to accumulate, making it difficult
to clean and adding expense to the sani-
tation cycle,” says Rick Zander, business
development manager for VDG (www.van-
dergraaf.com). “These arrangements are
“Just because a conveyor is stainless steel doesn’t necessarily mean it’s sanitary”
www.FoodProcessing.com
eHANDBOOK: Conveying / Sorting / Powder Bulk Handling 9
MORE THAN A CHECKWEIGHERCheck Weight for Quality and Control
800-472-6703www.ricelake.com/motoweigh
Rice Lake Weighing Systems’ MotoWeigh® In-Motion Checkweigher and Conveyor System combines automation with powerful weighing features to provide users complete control over their conveying processes. Designed with food-grade stainless steel and remote access capability, the MotoWeigh gives food processors an edge over the competition.
Industrial-strength equipment for the most demanding jobs.
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susceptible to foreign material contamina-
tion due to the wear of the plastics that can
end up in the food product.”
VDG’s drum motors, Zander says, avoid that
problem by having the motor, gearbox and
all other moving components inside a sealed
box. This protects the drum motor to the
extent of giving it an IP69K washdown rating,
meaning it can be sprayed with chemical
solutions up to 3,000 psi. It also connects
directly to the belt without sprockets, avoid-
ing the crevices and gaps they create when
connected to monolithic plastic belting.
Power-transmission components present
another potential source of contamina-
tion: the oil used to lubricate them. Most
food plants use food-grade lubricants for
this purpose, but that just reduces the risk
instead of eliminating it. Key Technology
offers drives for its vibratory conveyors
with oil-free vibrating motors, which elim-
inate the gearbox and drive belts – and
their lubrication.
RIDING THE TUBE Conveyors that carry products through
tubes present unique challenges in
sanitation. Whether they use pressurized
air or physical components to move
powders and bulk solids, their enclosed
interiors are harder to access.
When such a conveyor uses disks to move
product, it presents the additional challenge
of cleaning the forward-facing surfaces of
those disks. But conveying with physical
action means that cleaning can also be
done with physical action.
Carl Seidel, marketing director for Cablevey
(www.cablevey.com), says that cleaning
out Cablevey’s disk-based conveyors with
water is an option, but one that most end
users prefer to avoid.
“For the most part, people don’t want to
introduce [water] into any kind of process-
ing environment that they don’t have to,”
Seidel says. Cleaning with water limits pro-
cessing time because it must be dried off.
Instead, Cablevey offers a urethane “pig”
that can be dragged through its tube con-
veyors to clean them out routinely with each
run or product change. More thorough clean-
ing with water can be done every week or so
with a sponge-based attachment.
An advantage of the urethane pig is that it
can accumulate fine material, such as coat-
ing particulates that fall off product particles
during conveying, and make them available
for reuse. “Material is often reclaimed, now
more than ever,” Seidel says.
Keeping conveyors sanitary is no small feat,
given their size and complicated nature. But
with the right materials and design, it can
be done routinely while maintaining effi-
ciency in material handling.
www.FoodProcessing.com
eHANDBOOK: Conveying / Sorting / Powder Bulk Handling 11
Online Configuration and Quoting at qcconveyors.com
HYDROCLEAN SERIES
• Stainless Steel, sanitary conveyor design that is NSF & BISSC Certified
• Tail flips up with easy-to-use pull pins for efficient cleaning
• Tool-less belt, drive and tail removal for in-depth cleaning
• Slider bed is self draining and fasteners are designed to reduce opportunities for bacteria growth
• Easy to integrate with other machinery
FAST, EFFICIENT
CLEANING
HC200
It is important to know before purchasing
or repurposing any pneumatic convey-
ing system, whether the powders or bulk
materials may be difficult to convey.
Although it is a challenge to move diffi-
cult powders with a pneumatic conveying
system, it is not impossible.
“Difficult powders” are materials with
poor flow properties that do not want to
move. Cohesive and lightweight powders
such as carbon black, ultra fine particles,
non-granular powders, TiO2, calcium
carbonate, and substances known in the
industry as “conveying mud” – iron oxide,
zinc oxide, and toner – are very fine, sticky
and difficult to convey at 2,000-5,000 lbs
pr/hr or (907-2,268 kg. pr/hr), rates typi-
cal in many industries.
The main challenge in moving these pow-
ders is getting them into the conveying
line from the pick-up point, feeding them
Factors to Consider When Sourcing Pneumatic Conveying Systems for Powders That Are Difficult to MoveBy Vac-U-Max
Typical VAC-U-MAX Powder-HandlingReceiver for Batch & Continuous Operation
eHANDBOOK: Conveying / Sorting / Powder Bulk Handling 13
www.FoodProcessing.com
at a constant rate, and getting the powder
to discharge from the material receiver.
Once the non-free flowing materials are
entrained, they are fluidized and convey
easily and do not build up on the convey-
ing tubes.
When non-free flowing material is intro-
duced at the pick-up point, some bulk
material may go in but it could bridge or
rat-hole at that point. If the bulk material
does not flow down into the pick-up point,
only air will be conveyed, not product.
There are several options that make it
possible to get sticky or non-free flowing
materials into a conveying line at a con-
stant rate. It is critical to have the proper
solids-to-air ratio. If it is too high, the line
will plug. If it is too low, the pneumatic
system sucks-in mainly air and does not
transport much material.
One way to enter bulk materials at a con-
stant rate is to introduce the material
into the convey line where the air flow is
mechanical, typically with a rotary valve,
or physical, typically done with a screw
feeder. Other ways to help mechanically
move the powder or bulk material, and
ensure the correct solids-to-air ratio, is
with the aid of specially devised flow
promotion devices, specifically vacuum
receivers and suitable filters placed in the
correct locations. Flow promotion devices
can be vibration on the outside of a bin or
hopper that knocks the material loose, or
a small air cannon that injects air into the
material to prevents it from sticking to the
hopper and feeder walls.
When repurposing a conveying system, a
common problem is that it will not work
with new or other bulk material. It is
important to evaluate every single powder
that is difficult to convey. Even small dif-
ferences, like processing plants that have
two locations, each using powders from
different suppliers or different grades
and material characteristcs, all may have
an impact on processing, production and
end-product quality.
There are different grades of calcium car-
bonate, which when mined from the earth,
is rocky and free-flowing. The more it is
milled down to a superfine powder, the
more cakey and sticky it gets.
Download the complete white paper here.
It is important to evaluate every single powder that is difficult to convey. Even
small differences ... may have an impact.
www.FoodProcessing.com
eHANDBOOK: Conveying / Sorting / Powder Bulk Handling 14
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Food_Processing_7.875x10.5-for_eHandbook.indd 1 8/13/2019 1:48:08 PM
Food grade conveyor systems are
necessary to automate food pro-
cessing and manufacturing plants.
Food grade conveyor systems are a crit-
ical element in the facility’s operational
efficiency and ultimately, the company’s
profitability. Conveyor technology is
advancing, and there are several things to
consider before automatically choosing to
purchase another stainless steel conveyor.
The following checklist can help you deter-
mine what type of conveyor system is
most suitable where operational efficiency
and profitability are of high importance:
EASE OF CLEANING In the food processing industry, the
ease with which you are able to clean
a conveyor system is imperative. Look
for food grade conveyor systems that
offer a simple design that is easy to take
apart for quick cleaning and sanitizing.
A good design will allow you to take
the conveyor apart without the use of
tools. Make sure all equipment parts
are accessible for cleaning and are
self-draining with no product or liquid
collection points. Consider the color of
your conveyor. Conveyor color, such as
blue, can aid in the visual identification
of soil and food particles. With the right
conveyor, you can greatly reduce your
risk of product contamination and recall.
LONGEVITY The right conveyor system will be made
of components that are chemical- and
corrosion-resistant in order to handle
the rigors of frequent cleaning and
sanitizing. Conveyor sidewalls and
product retaining walls made of plastic
will not splinter, rot or retain harmful
Food Grade Conveyor Systems: What You Should Know Before You BuyBy Dynamic Conveyor
eHANDBOOK: Conveying / Sorting / Powder Bulk Handling 16
www.FoodProcessing.com
bacteria, odors or cleaning agents. When
made of impact resistant plastic material,
conveyor components – including
conveyor sidewalls – are cost-effective
to replace when damage is done or
conveyor design changes are needed.
COST OF OWNERSHIP Look beyond the initial purchase price
when considering the cost of the
conveyor system. Don’t forget to consider
the cost of operating and maintaining
the system. The labor and resources
needed for cleaning the conveyor can
quickly become your largest cost. Look
for a conveyor with minimal parts and the
ability to clean it quickly and efficiently.
Remember, you want your conveyor
to spend most of its time making you
money, not costing you money.
EASE OF MAINTENANCE Maintenance and uptime can affect
productivity. Determine what type of
maintenance your new system will need.
Consider motors with a hermetically
sealed design that ensures internal parts
are not exposed to external environmental
conditions and tampering. Look for
feed rollers that are bearing-free and
tensionless belts that are self-tracking.
BELTING OPTIONS Choose a vendor that offers a wide
range of belt types and styles. The
option to choose solid-surface, link
style or metal mesh belting for your
conveyor will give you ideal conveyance
of your food product whether it is dry,
wet or sticky. Look for food grade
conveyor systems that include belting
that is self-tracking, provides good
wear, performance, and service.
SAFETY As with any mechanical and electrical
device, conveyors can present some
safety concerns. Look for a conveyor
system where all of the moving parts
– such as chains, belts and sprockets –
are not accessible to fingers, hands and
loose clothing. The safest conveyors
are designed without sharp edges and
ensure that all moving parts are self-
contained or guarding is in place.
If you are still unsure which system will
serve you best, consult a conveyor expert.
Work with a conveyor manufacturer who
will partner with you to design the ideal
system for your needs.
Contact us for a free food grade conveyor
system assessment.
Download the complete white paper here.
www.FoodProcessing.com
eHANDBOOK: Conveying / Sorting / Powder Bulk Handling 17
Conveyors designed for easy and efficient cleaning and sanitizing.
231.798.1483www.DynamicConveyor.com
As food processors grew into the
20th century, the use of convey-
ors was initially thought of as a
transport method but has evolved to be
an integral part of producing large quan-
tities of food to supply an ever-growing
population. It became evident that there
was a need to streamline the handling of
food ingredients and products while uti-
lizing drums, containers, pails and mixing
equipment but the manpower required was
holding back growth. Although the use
of conveyors was initially thought of as a
transport method, they have evolved to be
an integral component to produce larger
quantities of food at quicker line speeds.
The first conveying equipment was made of
steel, aluminum, wood or whatever some-
one could muster up to do the job. Use of
cotton belting was quite common as it was
cost effective and readily available. Eventu-
ally, belt providers developed methods to
laminate covers made of a variety of resins
that allowed for cleaning the surfaces.
Although this was a major step in improving
the quality and sanitation, it wasn’t until
the introduction of new synthetic materials
which allowed for better cleaning surfaces,
strength and flexibility.
Today’s 21st century food-carrying convey-
ors have come a long way from inception.
Applications in meat and poultry, seafood,
baking, confections, fruits and vegetables,
prepared foods, frozen food and dairy-
based products have all benefited from
the newly developed conveyor designs.
But along with the benefits come capital
expense, maintenance, repairs and even
replacement, let alone government com-
pliance and stringent requirements from
food retailers.
CLEANING AND COMPLIANCE Food processing applications that store,
elevate, transfer and maintain patterns
for downstream packaging in many
cases are being utilized 24-7. Continuous
handling of the raw products can
(sometimes) create unsanitary conditions,
especially as product line demands
Evolution of Conveyors in Food ProcessingBy Multi-Conveyor
eHANDBOOK: Conveying / Sorting / Powder Bulk Handling 19
www.FoodProcessing.com
outweigh the need or time required for
regular cleaning and maintenance.
Changing of shifts, crews, contract cleaning
services and construction are some of the
issues requiring special attention to main-
tain sanitary operations. Numerous times,
the handing over from one shift to another
creates inconsistent conditions.
When agency inspectors arrive, manage-
ment should welcome any reports indicating
non-compliance as an incentive for personnel
to adhere to the sanitation standard estab-
lished and immediately comply to correct the
issues. These reports are also instrumental in
the design of future equipment, to make sure
it’s agency compliant from inception.
Belts are usually fastened at each end with
a variety of techniques. Belt splicing is done
in a variety of methods from hot vulcani-
zation, cold vulcanization or mechanical
splicing. Usually endless hot vulcanized
belts last relatively long; however, once
they require repair or replacement, the con-
veyor design becomes critical.
Many newer designs allow for the complete
disassembly of the conveyor for cleaning
using the NTR (no tools required) approach.
These designs promote time-saving belt
cleaning, repair or replacement.
NTR belt removal takes mere seconds/
minutes, allows for easy maintenance and
simplistic changeovers, alleviates unnecessary
toolboxes and tools for increased operator
safety. The tool-less pin-pull approach allows
the operator to remove the belt in mere sec-
onds for routine maintenance.
Belt cleaning and inspection lifts are a
useful addition and are simple in design.
Additionally, lifting the belt from the bed
section allows the belt to air dry if condi-
tions allow, otherwise, belt cleaners are
commercially available. Spray heads are
another option that can use heated water
if necessary to clean the top surface and
bottom sides of the conveyor return path.
More sophisticated belt washing systems
may include dryers and programmed clean-
ing cycles with duration options.
Download the complete white paper here.
Multi-faceted sanitary washdown urethane belt conveyor for accumulating bulk unpack-aged product.
www.FoodProcessing.com
eHANDBOOK: Conveying / Sorting / Powder Bulk Handling 20
Multi-ConveyorYour best...conveyed better.www.multi-conveyor.com1-800-236-7960
ProudMember
CONVEYORSSanitary. Hygienic. CIP. Washdown.
Often copied ... never equaled.