Pet meals processors typically depend on tubular drag cable conveyors to maneuver delicate supplies and powders, so it is essential to correctly design, set up and proactively preserve these methods to attenuate manufacturing downtime and maximize longevity.
In at this time’s fast-paced pet meals processing surroundings, it is a normal observe to run conveyors till one thing breaks or must be repaired, which might result in important pointless downtime.
“Processors historically have relied on third events reminiscent of native millwrights to put in and preserve conveyors,” stated Fernando Mejia, director of Product Life Cycle Administration & Aftermarket for Automated Dealing with Options (AHS). “These third events might not have entry to technical specs or haven’t had the chance to learn the guide and may subsequently be unaware of system acceptable specs and greatest practices. This may end up in not solely extreme downtime and upkeep, but in addition expensive repairs and even untimely system substitute.”
AHS brings collectively two corporations, Cablevey Conveyors and Spiroflow, to supply prospects with a specialised dealing with and automation product portfolio for mission-critical functions.
For pet meals processors, as an alternative of reacting to particular person issues as they come up, a simpler strategy is to implement whole preventative upkeep (TPM) for conveyors. This includes ongoing service and engineering assist, leading to lowered downtime and decrease operations and upkeep (O&M) prices.
“We’re right here to help prospects lowering their whole O&M prices,” stated Mejia. “We’re trying ahead to partnering with our prospects to examine their methods, evaluation layouts, and formulate a complete preventative upkeep plan primarily based on their wants. Failing on this, prospects might proceed to switch elements prematurely with all of the useless downtime this includes.
In line with Mejia, the aim of a TPM program is to work with our prospects to maximise the output of their conveyors and prolong the lifespan of their vital capital tools.
The aim of a complete preventative upkeep (TPM) program is to maximise the output of pet meals conveyors and prolong the lifespan of vital capital tools.Automated Dealing with Options
The worth of prevention
With the sophistication of state-of-the-art conveyors, proactive, preventative, and predictive upkeep is an efficient technique. That is the case with tubular drag cable conveyors, which gently transfer product by means of a sealed tube utilizing a coated, versatile stainless-steel drag cable pulled by means of on a loop. Strong round discs (flights) are connected to the cable, which propel the product by means of the tube with out the usage of air.
Whereas it’s potential to make use of third events to set up the methods and in-house upkeep groups to take care of them, there are appreciable benefits to involving an OEM Supervisor, since they possess unparalleled coaching and experience on the system. OEM technicians sometimes have years of expertise solely servicing and troubleshooting tubular drag fashion conveyors. These technicians have performed a whole lot of inspections in crops worldwide that run any materials conceivable, together with pet meals.
“Many recurring issues stem from incorrect set up, which might contain improperly positioning the conveyor’s hangers, extreme stress, misaligning tubing, leaving gaps, or inadequate helps,” stated Mejia. “All these defects can generate friction, noise, and prematurely put on elements, requiring substitute.”
An OEM may proactively suggest the suitable spare elements kits or excessive put on elements reminiscent of cables, connectors or sweeps which might be recognized to have shorter lifecycles. This technique encompasses assessing each the situation and utilization of the conveyor, whereas additionally leveraging predictive information to effectively resolve quite a few points earlier than any downtime happens.
“Because the OEM, we will analyze system utilization in addition to part put on and lifecycle information to precisely predict when important elements will doubtless must be changed and have them changed earlier than one thing breaks,” stated Mejia. “The extra a processor adheres to this kind of whole preventative upkeep schedule, the extra doubtless the conveyors will present optimum service all through their anticipated lifespan.”
To optimize manufacturing and prolong the lifespan of tubular drag cable conveyors, it is best to contain an knowledgeable OEM for whole preventive upkeep.Automated Dealing with Options
Complete annual inspections advisable
A complete annual inspection of the conveyor system by the OEM is very advisable. With the scarcity of expert mechanics mixed with excessive worker turnover, we’re right here to carry out in-depth inspections and advisable upkeep. This answer is especially focused to processors which have one or a number of tubular drag conveyors working consistently all through the yr.
In line with Mejia, detecting issues reminiscent of gaps or misalignments requires digital camera inspection. The annual inspection additionally assesses the conveyor’s tubes, partitions, sweeps, connectors, enter, and output. In addition, cables ought to be checked for integrity and stress, discs and sprockets for put on, and joints ought to be validated.
In the course of the inspection course of, the OEM can recalibrate or exchange any elements outdoors of system specs. Service technicians additionally advise on the usage of any obtainable replace or retrofit kits that may additional facilitate elevated output.
Whereas the frequency of the annual service visits relies on the system utility and surroundings situations, a number of elements can assist decide the optimum frequency. As a partial checklist, this could embrace the sort of conveyor methods within the facility, system size and complexity, common each day use, surroundings situations and the kind of materials conveyed. When these elements are analyzed, a service go to is perhaps scheduled a couple of times per yr, because the state of affairs warrants.
Many pet meals processors can profit drastically from collaborating with a educated conveyor OEM to determine a complete preventative upkeep plan. As an illustration, Mejia highlights the case of a processor that aimed to revamp their upkeep technique.
This buyer had expanded operations and was about to double their capability. Though their conveyors had been working properly, they didn’t need to threat pointless downtime. “So, they informed us, ‘We want to keep away from the ‘break/repair’ strategy and transfer ahead to a complete preventative upkeep tradition,’” stated Mejia. “I used to be thrilled to listen to that our aim and imaginative and prescient had been aligned.”
To fulfill the calls for of the pet meals trade and deal with the requested companies, AHS is rising their service capability to help processors in proactively mitigating points and minimizing downtime. The OEM will likely be establishing a service hub and elements depot on the West Coast, enabling localization, onsite inspections, and complete preventive upkeep by certified technicians with a neighborhood presence.
The OEM is now providing long run service agreements that can comprehensively cowl all facets of upkeep, so the pet meals processor can give attention to their core enterprise with confidence within the efficiency of their conveyors.
Del Williams is a technical author primarily based in Torrance, California.
