Mepaco’s Service Team is often called out on critical downtime situations. The goal for any food processor is to prevent these situations and if they are unavoidable, mitigate the time and cost associated with the breakdown. To start with, here are the top four calls that Mepaco Services receive for emergency support:
Broken Shafts Agitators are failing when they start to develop cracks or start to rub the tub side wall of the processing equipment. Agitators and shafts also fail when a tool or component drops into the equipment and damages the shaft or paddles. The damage is not always immediately apparent; a bent shaft may take months to start failing.
Gear Motors / Gear Boxes Oil leakage, hot temperatures and noise are all signs that gear motors or gear boxes may be failing. The motors and gear boxes commonly fail due to poor lubrication practices. They also may fail because of improper repair of the agitator and the gear motor and gear box may wear out prematurely.
Safety Devices Equipment is designed with safety modes and if the safety devices are damaged, whether accidental or environmental, the equipment will not operate.
Controls Internal programming errors, or physical damage to the HMI are also causes for emergency downtime.
In most instances, there are preventative measurements for processors to prevent downtime situations, but what can you do to mitigate the critical breakdown situation and get back online as soon as possible?
- Self-Repair of Shaft Agitator with After-Event Service Call Mepaco Services does provide emergency repairs, yet there is travel time and scheduling to plan. Some processors have maintenance capabilities to make their own repairs. If the repair is viable by the internal maintenance team, be sure to schedule an after-event care assessment. Mepaco Services technicians will verify the repairs, fix if necessary and provide an assessment of the remaining life of the agitator. Agitators are a long lead parts component, so it is crucial to order the component if there is any indication that the existing shaft will not last.
- Emergency Replacement Program for Gear Motors / Gear Boxes Nord is a common component provider in Mepaco equipment. If your equipment has Nord gear motors or Nord gear boxes, the company does offer a weekend emergency expedite program. There is a premium price for the service, but some processors choose the pay it to avoid the cost of lost production. In some cases, the gear motors / gear boxes may be able to be reconditioned, and after repair they can be used as a spare.
- Safety Device Failure While it is not recommended, some processors have engineered workarounds on broken safety devices to continue to run the equipment. It is very important however, to schedule an after-event service call to return the system to the original safety features, programming, and controls. On new equipment, order spare safety switches, relays, and other controls devices so if there is any failure during transport, install or commissioning, that a new part is on hand to start production on schedule.
- Controls If there was unintentional change to the equipment software, in most cases it is possible for a remote programming repair or reloading of the original program. If the HMI was damaged by condensation from high-pressure, caustic washdown or accidental, a replacement may be required.
The Mepaco Parts and Service team strongly urges processing customers to consider a just-in-case planning mentally for parts replacement. There are long lead times on agitators, cylinders, motors, gear motors, safety devices and HMI panels.
After-event service calls or equipment-systems assessments are recommended to ensure production up-time and to alleviate safety risk. If you have questions, or to schedule service visit, call 920-356-9900 and ask for Mepaco Parts and Service.