Pet meals processors typically depend on tubular drag cable conveyors to maneuver delicate supplies and powders, so it is necessary to correctly design, set up and proactively preserve these techniques to reduce manufacturing downtime and maximize longevity.
In right now’s fast-paced pet meals processing atmosphere, it is a typical follow to run conveyors till one thing breaks or must be repaired, which may result in vital pointless downtime.
“Processors historically have relied on third events comparable to native millwrights to put in and preserve conveyors,” mentioned Fernando Mejia, director of Product Life Cycle Administration & Aftermarket for Automated Dealing with Options (AHS). “These third events could not have entry to technical specs or haven’t had the chance to learn the guide and may due to this fact be unaware of system acceptable specs and finest practices. This can lead to not solely extreme downtime and upkeep, but additionally expensive repairs and even untimely system alternative.”
AHS brings collectively two corporations, Cablevey Conveyors and Spiroflow, to offer clients 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 more practical method is to implement complete preventative upkeep (TPM) for conveyors. This entails ongoing service and engineering help, leading to decreased downtime and decrease operations and upkeep (O&M) prices.
“We’re right here to help clients decreasing their complete O&M prices,” mentioned Mejia. “We’re trying ahead to partnering with our clients to examine their techniques, overview layouts, and formulate a complete preventative upkeep plan based mostly on their wants. Failing on this, clients could proceed to exchange elements prematurely with all of the pointless downtime this entails.
In response to Mejia, the objective of a TPM program is to work with our clients to maximise the output of their conveyors and prolong the lifespan of their vital capital gear.
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. Stable 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 doable to make use of third events to set up the techniques 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 usually 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 possible, together with pet meals.
“Many recurring issues stem from incorrect set up, which may contain improperly positioning the conveyor’s hangers, extreme rigidity, misaligning tubing, leaving gaps, or inadequate helps,” mentioned Mejia. “All these defects can generate friction, noise, and prematurely put on elements, requiring alternative.”
An OEM may proactively suggest the suitable spare elements kits or excessive put on elements comparable to cables, connectors or sweeps which are 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 are able to analyze system utilization in addition to part put on and lifecycle information to precisely predict when very important elements will seemingly should be changed and have them changed earlier than one thing breaks,” mentioned Mejia. “The extra a processor adheres to this kind of complete preventative upkeep schedule, the extra seemingly 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 complete preventive upkeep.Automated Dealing with Options
Complete annual inspections really helpful
A complete annual inspection of the conveyor system by the OEM is very really helpful. With the scarcity of expert mechanics mixed with excessive worker turnover, we’re right here to carry out in-depth inspections and really helpful upkeep. This answer is especially focused to processors which have one or a number of tubular drag conveyors working always all through the yr.
In response to Mejia, detecting issues comparable to 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 needs to be checked for integrity and rigidity, discs and sprockets for put on, and joints needs to be validated.
Through the inspection course of, the OEM can recalibrate or substitute any elements exterior of system specs. Service technicians additionally advise on the usage of any accessible replace or retrofit kits that may additional facilitate elevated output.
Whereas the frequency of the annual service visits is dependent upon the system utility and atmosphere situations, a number of components can assist decide the optimum frequency. As a partial checklist, this could embody the sort of conveyor techniques within the facility, system size and complexity, common each day use, atmosphere situations and the kind of materials conveyed. When these components are analyzed, a service go to may be scheduled a few times per yr, because the state of affairs warrants.
Many pet meals processors can profit enormously from collaborating with a educated conveyor OEM to determine a complete preventative upkeep plan. For example, 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 have been working nicely, they didn’t need to danger pointless downtime. “So, they instructed us, ‘We wish to keep away from the ‘break/repair’ method and transfer ahead to a complete preventative upkeep tradition,’” mentioned Mejia. “I used to be thrilled to listen to that our objective and imaginative and prescient have 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 shall 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 concentrate on their core enterprise with confidence within the efficiency of their conveyors.
Del Williams is a technical author based mostly in Torrance, California.
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