A fast-growing ready-food manufacturer faced a serious technological problem — the conveyors in use were contaminating the product, leading to losses, rejects, and production downtime.
To eliminate the problem, Hapman tubular drag conveyors were installed. The new material conveying system completely removed the source of contamination, stabilized the production process, and ensured uninterrupted line operation around the clock.
Results appeared very quickly — the company eliminated product rejects, reduced downtime, and achieved a return on investment within just a few months of implementation.
The Challenge
The manufacturer used aeromechanical conveyors to move product between processing and pre-packing stages. As production increased, however, the existing technology began causing more and more problems.
The biggest challenges included:
- Worn and cracking conveyor components allowed metal fragments to enter the product. This resulted in a high number of rejected batches and created a risk of complaints and costly product recalls.
- Frequent jams and blockages in material conveying led to regular production stoppages. Equipment maintenance became a daily necessity instead of planned service work.
- The plant incurred losses in both raw materials and production output. The technical team spent most of its time fixing breakdowns instead of overseeing and optimizing the process.
In the food industry, where product safety and production continuity are critical, continuing to operate under these conditions meant rising costs and growing risk for the company.
The Solution
The existing pneumatic conveyors were replaced with Hapman tubular drag conveyors — a solution designed specifically for the safe, clean, and reliable conveying of food products and damage-sensitive materials.
Key elements of the implemented solution:
- A high-strength stainless-steel chain was used instead of wear-prone cables. This eliminated the risk of fraying, cracking, and metal fragments entering the product.
- The enclosed tubular construction protects the product from contact with the environment and reduces dust and contamination.
- The system was designed to minimize the risk of jams and ensure smooth conveying of food products.
- The conveyor’s construction requires little servicing and was built for continuous round-the-clock operation.
The key change, however, concerned the conveying technology itself. The new system contains no components that could release metal contaminants into the product as they wear. This completely eliminated one of the biggest threats to food quality and safety.
Results
The implementation delivered fast, clearly measurable results:
- The problem of metal fragments entering the product was completely eliminated.
- The production line now runs uninterrupted 24/7, with no jams or breakdowns related to material conveying.
- The maintenance team regained time for planned service work and process improvement, instead of constantly fixing faults.
- The investment paid for itself within just a few months, thanks to reduced raw-material losses, fewer stoppages, and increased available production capacity.
- Plant staff unanimously confirm improved process stability and greater comfort in day-to-day work.
If your plant is experiencing problems with jams, product contamination, or unreliable material conveying, get in touch with us. We’ll help you select a solution tailored to the specifics of your production.
