In spiral applications, overall equipment effectiveness (OEE) is important for not only cost savings but increasing throughput and limiting unplanned downtime. It can be overwhelming to know where to begin to optimize your conveyor lines to function at peak productivity. There are several key considerations to be mindful of when maximizing OEE to get the most out of your production.

Choosing the Right Materials for Optimal Performance

The first factor to consider is choosing the appropriate materials for your spiral application equipment. Utilizing components and conveyor belting that are the most functional for your application needs is critical when wanting to maximize OEE. The common conveyor belt materials of metal and plastic both have strengths and weaknesses that make either of them more suitable for certain use cases over others.

Metal belts are highly durable and can withstand heavy loads and harsh conditions, which can lead to a longer service life. They operate effectively in extreme temperature changes, are easy to clean and sanitize, and resist scratches and cracks that can harbor contaminants. If a piece of metal belt breaks off, it is more easily detectable, which helps in quickly identifying and removing contaminants. Metal belts provide precise and consistent performance, which is essential for maintaining product quality and reducing waste.

Plastic belts are modular and lightweight which can make maintenance and cleaning easier and more efficient. They can handle high impact loads without deforming and their solid, flat surface makes them ideal for conveying very small products. Surface treatments can be applied to plastic belts to enhance product conveyance and reduce the risk of contamination, along with the smooth finish of plastic belts to help limit the adhesion of biofilms. However, while these belts are initially smooth and easy to clean, they can develop scratches over time and create spaces for contaminants to hide.

Source: ©Regal Rexnord Corporation

Both metal and plastic belts are great for tight turn operations in spiral applications, are extremely chemical resistant, and can function well in food processing environments. Your specific application needs are key when determining which is right for you.

The materials of the other components on your conveyor line are also influential. IP67/IP69K rated and corrosion-resistant materials for bearings, couplings, gearing, and motors can increase OEE by extending the life of your equipment and making them more efficient. Ensuring you have complementary components that are optimized to work together as one system is also greatly beneficial. When each piece of your line can merge seamlessly, you can prolong the equipment functionality.

Minimizing Contamination to Ensure Food Safety and Efficient Operations

Minimizing contamination is crucial for meeting regulatory standards and maintaining customer safety. Food safety concerns are becoming increasingly pertinent. In the last year, there were numerous, highly publicized product recalls due to bacteria or contaminants in food. Foreign Material Contamination (FMC) refers to avoidable and unwanted matter, such as metal fragments, inside food products. When these foreign materials become present in food processing lines, at best they will cause product waste when detected and at worst can endanger customers and harm your company’s reputation.

Cleaning and sanitation are different but complement each other in maintaining food safety:

• Cleaning means removing dirt, debris, and contaminants from surfaces to prevent the buildup of substances that could lead to product contamination.
• Sanitation focuses on eliminating or reducing pathogens and microorganisms to safe levels, protecting the environment from harmful bacteria. 

Both are essential for ensuring a safe and hygienic food manufacturing operation and to reduce the risk of harmful recalls and product waste.

Equipment designed for easier cleaning can reduce the amount of water, chemicals needed, and labor time. This leads to more efficient operations and a safer environment. For example, open hinge plastic belting is better for critical sanitation applications because the exposed hinges allow for thorough cleaning and reduce the risk of debris accumulation. The ability to withstand harsh washdowns while also resisting buildup is key for food safety and sanitation.

How Proper Belt Alignment Can Impact a Conveyor Line

In spiral applications, belt alignment and proper installation is crucial to prevent product loss and costly downtime. If a conveyor belt is not properly aligned or maintained, the conveyor pulsation can cause product damage, such as misorientation, crushing, or tearing, creating waste and eroding revenue. 

Source: ©Regal Rexnord Corporation

Misalignment and improper installation can cause irreparable damage to a new belt, severely limiting its life cycle and efficiency. Spiral conveyor lines are essential for proofing, freezing, and cooling food products and require a lot of belt length. Downtime and replacement costs for these vital applications can be offset by investing in proper installation support to ensure the belt is installed correctly upfront to save on expenses down the line.

Other Factors to Improve OEE

Condition monitoring can help extend equipment life and eliminate unplanned downtime by utilizing remote sensors that monitor the components on your line and provide actionable reports to move from reactive maintenance to a predictive maintenance plan. Condition monitoring systems can increase productivity and meet stringent sanitation requirements with IP69K-certified sensors. Monitoring factors like torque to detect mechanical stress and fatigue, temperature, and changes in vibration can help eliminate costly unplanned downtime and increase the life of your equipment.

A gap walk, also referred to as a line audit, can identify the best ways to optimize your lines, address pain points, and find areas for improvement in your systems. Bringing in an engineering application expert to walk through your lines will provide an outside perspective on your challenges and can locate ways to save on costs, boost efficiency, and maximize your productivity. 

Source: ©Regal Rexnord Corporation

These experts want to understand your main areas of concern and can spot areas where there is potential to automate or optimize tasks. They can help you to understand the assets on your conveyor line or application to help reduce inventory, aid in replacements, and advance production. A gap walk can also assist with implementing any of the OEE considerations outlined above, from choosing optimal materials and minimizing contamination to alignment and condition monitoring needs.