Conveying systems: Upgrade, innovate, adapt (part II

Part 2: Upgrade, adapt

All systems go

Conveyor systems work under demanding conditions in bakeries. Maintaining them in top condition is the first step to efficiency in production; upgrades will then guarantee optimum performance in handling processes for truly competitive-level manufacturing.

+Conveying systems need to be improved to best ensure product transportation is optimized, according to the type of conveying system, the production steps of the line, and the type of products moved. The design of a reliable conveying system must consider the type of product, whether it’s pastry, bread, or patisserie, and its production process, which differs for raw frozen, pre-parbaked frozen, freshbaked goods, for example, to preserve the product quality. “To meet this challenge, the conveying system must avoid shocks, vibrations, sudden mechanical movements that could cause the deterioration of the product (e.g., deflating dough) and impact on the quality,” François Retailleau, Line Product Manager at Mecatherm, underlines. The conveying system must handle the products/bakeware without affecting the products, keeping its alignment throughout processing steps. The conveying system also must be able to adapt itself to the cadence of the line (acceleration and deceleration management) and be flexible and robust.

To answer current market needs for flexibility and product diversity, the conveying system can be part of these trends as a vector of line flexibility, contributing to several processes, from frozen raw products to fresh-baked or frozen products. The challenge is in the industrial performance: if the conveying system is well designed, it is possible to implement solutions in a fairly compact area, for example, or, in any case, to adapt to the customer’s environment.

Mecatherm’s solutions are based on modular conveyors, with switches that allow trays to be routed in different directions and adapted automation management. Retailleau provides an overview: “The MECAFLEX Line is agile architecture served by flexible equipment and enriched by smart software tools, which provides optimized productivity and efficiency to production management.” This flexible line thus allows to run fresh baked products at the same time as raw frozen products, thanks to a smart conveying layout.

Systematic cleaning

Amounting to 100-200m on a complete line, the conveyors must have few or no retention areas where dough residues can deposit. Sanitation procedures will also be adjusted to manufacturing specifics. A ‘basic’ environment with a dedicated bread line will follow a simple but complete sanitary procedure, for example, while an ‘intermediate’ environment complexity-wise will require additional steps, depending on the rigors of the ingredients used. Eggs and meat are relevant

examples in this case. In an industrial bakery environment, cleaning can be based on the following steps: + Cleaning dust + Minimizing/eliminating retention areas in the conveying system, to prevent the formation of dough residues + Periodic cleaning with a wet cloth while protecting sensors, motors and other electrical components that cannot be submerged in water

Retailleau also points out hygiene among important factors in the conveyor’s design: “To keep food safety all along the line, it is necessary to reduce the dough retention areas, which can lead to bacteria development, and have a conveying system that is easy to clean.”

Cleaning will be much more demanding for lines that frequently produce goods with higher water content, with eggs or perishable and sensitive meat products because of the risk of bacteria development. Food safety and hygiene are therefore key issues to be addressed. In this case, not only the conveyor's design should be adapted, but also cleaning procedures have to be reinforced: + Setting up a dedicated, full-time cleaning team + Thoroughly protecting the motors + Cleaning the conveyors with a combination of acid and basic detergents followed by a rinsing step The conveyor system must therefore be reliable, adapted according to the types of production, and easy to clean respecting the sanitary measures according to the customer's environment.

A close inspection of the belt

Maintaining a conveying system in its fully operational capacity is a prerequisite in increasing efficiency; upgrading it is then the next goal. One of the first elements to be closely inspected as it can provide significant process improvements is the conveyor belt. For baking, a steel belt can act as a window into the performance of the entire oven. For example, if side wandering tends to occur, this can often cause the belt to come into contact with the structure or another rigid object, resulting in burrs. Wavy edges could be another indication of side wandering, or uneven temperature in the oven. “It can also indicate uneven pressure from the belt cleaner or scraper, or a belt scraper that is wider than the belt itself,” Marko Leber, IPCO Global Product Manager, Food, illustrates.

To design solutions and upgrades, IPCO will look for deformations in the belt that could suggest problems with drums, belt supports or other parts coming into contact with the belt. Counter actions include cleaning the drums, cleaning or replacing belt supports, and checking scrapers, rollers and belt tensioning. The underside of the belt is also on this

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checklist and subject to inspection, as any scratches could indicate worn or damaged belt supports or safety scrapers. “We understand how a belt interacts with the many other components that make up the system as a whole. For our service teams, an analysis of the condition of a belt gives us an insight into how an entire system is performing,” Leber explains.

A comprehensive conveyor analysis

IPCO is a belt specialist first and foremost, but almost 100 years experience of working with the bakery industry has given the company an insight that goes beyond the design and supply of solid and perforated steel belts. The Swedish company can provide support in the form of a full range of conveyor components. Such was the case of a customer experiencing constant problems with a line, for example: while they initially intended to replace the belt, IPCO analyzed the equipment and identified a deeper issue for which it recommended a more elaborate solution, in addition to replacing the belt. It included a new tracking system, replacement tensions and drive drums, scrapers, spring guide rollers and a combination of cast iron and graphite skid bars. “The result was a complete system upgrade, designed, supplied and installed by our teams,” Leber summarizes.

In most cases, the condition of the belt is the symptom of a problem and not the cause. That is why IPCO recommends regular belt inspections. In another recent case, a customer experienced belt tracking problems which, on close inspection, turned out to be caused by several components in the 1970s-built oven, and completely unrelated to the belt itself. These parts were not able to provide the reliability and performance of modern conveyor equipment. The surfaces of the drums, for example, were no longer suitable for effective belt tracking. IPCO retrofitted a range of new components, including inlet and outlet drums, new tracking devices, a graphite station and a cleaning brush and scrapers. The existing belt did not require replacing. “The customer ended up with a state-of-the-art conveyor system capable of delivering significantly improved productivity, with lower costs than it would have been for a new belt.”

Conveying for the process

Several aspects determine what improvements a conveying system needs – starting with the process step it serves. Luis Patricio, Intralox Baking Account Manager, lists: + The work environment and the product conveyed. These will define the type of chassis frame construction and belt material to be used for the right application and surrounding environment. + Health and safety aspects, if people are working on the surroundings to prevent possible hazards. + Preventative maintenance plays a key role in the costs of ownership and operation reliability. “As the industry is moving fast into a direction of minimal costs to run operations, conveyor systems (including spirals) with low cost of ownership will play a key role moving forward,” Patricio adds.

Intralox developed a new type of belt material (PK) for its modular belt series. “This material is stronger than Acetal and has very good product release characteristics,” Hans Tertoolen, Intralox Bakery Account Manager explains. The PK material for modular belts shows excellent product release characteristics, making it a choice for higher hydration doughs, for example. The company’s ThermoDrive belts also excel at handling wet, sticky doughs; they are “Flat belts made of a homogenous PU material with a patented tensionless drive system based on the same principle as our modular belts,” explains Patricio.

For more upgrades, the company’s latest solutions also include a new type of tight transfer modular belt, the S560 series, a strong belt with an upgraded sprocket engagement. Over the past months, Intralox has launched several new belt series, materials and technologies for hygienic applications, spiral technology and P2P (Packer to Palletizer).

When working to optimize new bakery lines with conveying systems, Intralox works closely with the end-users to understand their needs for specific applications. In parallel with OEMs, the company provides support to ensure the right application is in place, corresponding with the manufacturing needs. For manufacturers looking to upgrade existing equipment, Intralox has a specialized engineering department focused on improving existing applications, including complex applications such as spirals.

You can read more about maintaining conveyor systems and process optimization in the previous issue of Baking and Biscuit International. +++