Mepaco Blog

With the complex demands in food processing and production, safety, and quality, performance of every component within food equipment is critical.

The bearing type and style for your Mepaco equipment has been determined by application and plant preference.  Many food processing facilities utilize stainless bearings which provide corrosion resistance in wet environments. Here are some tips to reduce wear issues and extend stainless food-grade bearing life:

1. Mount the bearing correctly after maintenance. Make sure shims are re-installed and that the shaft is correctly positioned, and that the shaft and bearing housing have the correct tolerance. A bearing sitting loose on a shaft will cause significant damage.
2. Grease bearings according to manufacturer recommendations. One grease schedule does not fit all bearings. For example, a low RPM bearing on a mixer will not require grease as often as a grinder gearbox bearing.
3. Use the correct food-grade lubrication in the right quantity. Over-lubrication can blow out the grease seal, under lubricating can increase friction and cause failure.
4. Check bearings regularly for excessive play and replace bad bearings before they cause damage to the equipment. Replacing a bearing is much less expensive than replacing a worn and grooved shaft.
5. Seals provide extra protection for bearing lubrication while preventing contaminant entry.  Seals protect bearing lubrication by keeping moisture, dust, and dirt out of the bearing; make sure seals are inspected and maintained properly. End covers for housed units solve for issues for exposed shaft ends and workplace health and safety.

Choose the bearing type that will uphold to the food processing application. Standard steel ball bearings are mounted in a painted cast iron housing. Mepaco’s coating on standard bearings is a sealant with anti-corrosive benefits.

In aggressive and gritty food product applications, food processors often choose polymer bearings. The polymer bearing has a moderate up-front investment – but the total cost of ownership is lower because it requires less maintenance when used in aggressive applications.

Our service techs, engineers, and application experts have pinpointed the five most congested production areas in food manufacturing plants. Here are their tips for mitigating these delays, starting with the loading of a system:

#1 Bottleneck: Inefficient and Ineffective Loaders

A common bottleneck is slow loading times preventing the start of batch mixing or blending. Some processors struggle with effective loading using non-integrated, manually intensive equipment causing higher than expected load times and product waste due to ineffective design for the application.

Ineffective feeding methods also add to processing bottlenecks including delays in food product barreling and other issues with non-positive conveyance.

Mitigation:  While some efficiencies may be gained from an efficiency audit, new equipment solutions might be considered with an integrated recipe and process control package that drives automation. Depending on the consistency of the product, Screw conveyor and Belt Conveyor systems can be designed for the application to provide the necessary feed rate to load quickly and efficiently while maintaining product integrity and temperature. If the product must be delivered from a buggy, combo or vat, Column Dumpers or Vat Dumpers can also be designed for the application and fully integrate with the system.

#2 Bottleneck: Over-blending

While it seems like systems will gain more throughput from over-filling, it creates the opposite effect of over-blending and is a waste of production time and efficiencies. The consequences of over-blending are extended load/discharge and blend cycle times. A slight increase in the batch size leads to losses in the overall production rate, sacrificing quality and accuracy.

Some production bottlenecks are caused by inefficient feed rates or lack of surge, causing another case of over-blending.

Mitigation: The process may benefit from a different agitator to produce a quicker, more effective blend. It may also be a process issue where the recipes and timing require tuning to control the blender more efficiently.

The system may warrant an efficiency audit and adjustment to reach the gains and efficiency possible from the equipment. Some customers schedule yearly efficiency audits, having discovered that the service calls pay for themselves in improved quality, accuracy, and throughput.

An efficiency audit may address inefficient feed rates, or a new equipment solution with surge loading may offer more automation.

#3 Bottleneck: Overtaxed Agitators

Mixers and Blenders are the workhorses of a food processing line. It is vital to keep them well maintained. Flexed or stressed agitators do not perform efficiently and in some cases minor efficiencies turn into critical downtime scenarios when not maintained properly.

Mitigation: The drive end motor may not be shimmed properly. A bad bearing on the idle side may be creating flexing in the agitator. Over chilled food product will cause additional stress on the agitation process.

It is critical to understand the expected performance of your mixer or blender as well as the maintenance and inspection of the agitator(s). If plant personnel make a repair, it is important to schedule an after-event service call to make sure the repairs hold up to stainless welding fortifications and proper straightening to prevent future issues. There is a 3-month to 6-month lead time on replacement agitators. High volume processors often keep a spare agitator in inventory in the event of a critical agitator repair, so production can continue using the inventoried agitator.

#4 Bottleneck: Cooker Scraper Damage and Performance

Batch cookers set the pace for downstream processes and production goals in a prepared foods production line. It is not uncommon to run cookers for long periods, especially by high-volume producers. Scraper systems may degrade prematurely when preventative maintenance is stretched too far between intervals. Worn scrapers are a liability to food safety and product quality that can cause a critical shut-down if scrapers crack or break up into the food product; or become ineffective due to excessive wear.

Mitigation: Mepaco® field services experts recommend always having a complete set of scraper assemblies (including springs) in inventory.  High volume processors often create blanket orders to maintain a steady inventory of scraper assemblies. 

A preventative maintenance check on the scrapers is just as important to prevent downtime associated with scrapers.  Evidence of product burn-on and product build-up is a sign that the scrapers are worn. It is important to note scraper usage compared to the hours of operation.  Maintenance checks and sanitation protocols should include checking scrapers for cracks, missing pieces, and other signs of stress or wear.

#5 Bottleneck: Manual or Inefficient Unloading

When cookers or mixers are manually unloaded into buggies or vats, several minutes of production are lost compared to automatic solutions. The equipment must be shut off, the operator must manually remove product around the doors, then close the doors before taking the tote by fork truck to the dumper.

Mepaco® techs have also seen delays with unloading when downstream equipment is not ready or can’t keep up with the cooker or mixer.

Mitigation: In manual unloading situations, equipment such as screw conveyors, metering screws or pump feeders may be able to be planned into the system to automate the process, even as a retrofit, if the floor layout allows. 

In situations where downstream equipment does not allow for product, Mepaco® has engineered buffering mixers, which will maintain the mix and the temperatures, in a holding state until signaled by downstream equipment. The blender can continue production when the previous batch is discharged into the buffering mixer.

The greatest efficiencies in a processing system result from a coordinated effort to automate the processes in the system by determining:

• Feasibility for combined cooking and blending operations utilizing fewer equipment solutions
• Reduced cooking and cooling cycles integrating CO2 or vacuum
• Integrating accumulation and buffering to drive continuous production
• Smart controls that engage simultaneous processes to prevent gaps in machine processing time

 

 

This featured system doubled cooking batches within a minimal footprint used well-planned equipment selection, floor layout, and controls customization. Mepaco®'s cooking system featured side-by-side ThermaBlend® cookers, with a shared maintenance and sanitation platform.  

SYSTEM FLEXIBILITY
The multi-recipe prepared foods processor benefited from flexibility in production scenarios. The system can run two batches at once, staggered, or different batches in each cooker, all driven by production demand and recipe controls.

SYSTEM EFFICIENCY
The ThermaBlend® Cooker supports quick homogeneous batch turn for their multi-recipe production requirements. The wrap-around heat jacket design, bi-directional scraper system, and an application-specific agitator create cooking and blending efficiencies. 

Further efficiencies of the ThermaBlend® cooker include the variation of processing capabilities in one unit, such as cooking, searing, caramelizing, sautéing, and blending. A versatile unit, ThermaBlend®'s is designed for large-scale cooking operations. Customization such as integrating vacuum and cooling, also provides added efficiency.

The batches are discharged into a heated buffering mixer that maintains product temperature and consistency until signaled for release to downstream operations.

The opposite cover design on the dual cookers with the shared platform and the electropolished food contact surfaces create a high degree of sanitation efficiency.

SYSTEM RELIABILITY

The system is highly controlled and reliable. Mepaco's ThermaBlend®'s are engineered with extremely robust stay-bolt ASME-rated jackets. Cookers are customized to the application, including experienced agitator designs to meet rigorous production requirements.

Two column dumpers are used to add ingredients to two ThermaBlend® cookers.  The Mepaco® Column Dumper offers a very heavy-duty design and is engineered for maintenance ease.  Mepaco® often makes modifications depending on the application, such as column heights, dump angles to 60 degrees, dumper capacity, extended chutes, and stainless upgrade kit.

Mepaco® has a new test cooker for processors with new products or recipes requiring cooking and blending. The test cooker is a 75-gallon ThermaBlend® unit with steam injection, vacuum, pneumatic covers and doors, and dual ribbon agitators. Learn more about scheduling a trial. 

The Mepaco® brand has been around for a long time. The company began in 1932, and we are well known for our blending systems. Mepaco®'s team of long-standing technical sales managers, engineers, and project leaders work with customer teams to solve for the best solution that fits the application and production goals. Our equipment and systems uphold increased yield performance, optimal designs for ease of maintenance and operation, single-source manufacturing capabilities, the highest sanitary equipment finishes available and vigilant compliance of food safety criteria.

Case Story: What can happen when an agitator problem is ignored?

A high-volume pet food processor utilized a Mixer/Cooker in their operations which produced 45-minute batches.  The application called for 28 RPM and mixing cold product at 35 – 45 degrees. During the process of loading different ingredients into the Mixer-Cooker, a Vmag buggy fell into the mixer, causing damage to the agitator.

The processor made repairs to the bent shaft and paddles and was able to get the Mixer-Cooker back online into full production. 

Many processors assume that if the paddles do not rub the side of the tub, that the agitator has had a successful repair. But in many cases (and in this case), there was extensive damage and over time the shaft began to flex, causing the agitator to break. This failure completely stopped production.

There are a few choices to stay ahead of agitator care:

Preventative Maintenance:  Partner with Mepaco Services to inspect agitators to ensure the shaft is straight and look for stress and other damage.

After Event Care: Processors may be able to fix the shift to continue production, but contract with Mepaco Services to inspect the shaft and straighten if necessary.

Most importantly, processors should avoid emergency maintenance, causing down-time and lost production. 

It is not uncommon to have dropped tools into Mixers, so prepare for the event if it does happen.  Consider an audit to assess the life of the agitator and consider ordering a replacement so you can have duplicity for uninterrupted down-time. 

Delivery of agitator replacements are 3 – 6 months out due to the availability of stainless material.  Mixers, Blenders and Grinders are the work horse of the processing system, so be sure that agitator care and component availability are part of the maintenance program.

Mepaco Services offer on-site audits, training, and service contracts as well as emergency repair.

 

1. Safety guarding is recommended on equipment like the dumper shown in the animation.  Relays control the e-stop position and if personnel trips the switch, the equipment will cease operation.
2. This PRS (Pallet Retention System) shown on a DP3000 Dumper, and allows the combo to complete the dump cycle by separating from the pallet, limiting the potential for contamination.
3. A liner hold-down prevents the liner from separating from the combo and falling into the hopper.
4. A drop-tier conveyor can be included in system layouts to provide visual inspection of the food product.
5. The articulating screw conveyor is designed to pivot to allow for versatile production and lower for maintenance.
6. Custom stainless and passivated platforms provide personnel safety and easy access for sanitation.
7. Electropolished food contact surfaces guard against bacterial attachment and create sanitation efficiencies.
8. Tool-less quick-release seals provide quick access for maintenance and sanitation.
9. Durable food safe coating on equipment components resists corrosion in harsh environments.
10. Type 304 or 316 stainless construction is a best practice for equipment designs using either open-frame construction with exposed threads or tube frame designs with non-exposed threads.

 

 

 

If you would like to learn more about food safety and sanitation equipment innovations trending in food processing equipment and systems, we are offering a Lunch & Learn presentation.  

Discover:

• Food processing equipment that is customized to specific applications and to scale
• System examples with animation and video that solve processing throughput
• Sanitation design options and best practices
• Maintenance and food safety driven innovations

 

Our focus will be to customize this presentation to talk about your production needs, and safety and sanitation goals.

We will monitor COVID-19 travel and distancing regulations and if allowed, we can have the Lunch & Learn at Apache Stainless or at your facility. Just let us know and we will take care of lunch.

We will also offer a virtual meeting if that works best, and we will send attendees a gift card for lunch on us!

We look forward to hearing from you!

Contact a technical sales manager to schedule!

2B Mill Finish – This is a widely used stainless steel finish, common in industrial, chemical and food applications. It is corrosion resistance and has a typical range from 15RA (16 gauge) – to 40 RA (7 gauge) microinches.

No. 4/Dairy Finish – For processing industries, the Dairy finish is required to meet the basic 3-A standards. It uses a 180 grit and has an RA range of 18-31 microinches.

No. 4 Finish – This finish uses a 150-grit abrasive creating a polished brushed surface. The RA range is 29-40 microinches.

No. 3 Finish – The No. 3 finish uses a 120 grit abrasive. It has a semi-polished finish with an RA range of 36 – 58 microinches.

Bead Blasted surfaces have a soft satin appearance and low reflection.  The process of bead blasting utilizes bead material such as glass or ceramic beads to produce a non-directional, textured surface.  The finer the blasting media, the more corrosion resistance the surface performance. The RA values are typically higher than 45RA microinches, but are dependent on the blasting process and the stainless material.

Improve your Stainless Finishes IQ; read our complimentary e-book.

An equipment safety and sanitation audit can provide direction for implementing improvement procedures and specifying equipment updates that mitigate risk and solve for safety and production goals.  Here’s an excerpt from our audit checklist:

• Are all parts of the equipment readily accessible for inspection, maintenance, sanitation?
• Is there any evidence of premature wear on parts?
• Does the equipment properly self-drain to assure food product, water or sanitizing fluids do not accumulate?
• Are all hollow areas removed where possible or permanently sealed to eliminate any harborage areas?
• During operation, does the equipment perform properly as not to contribute to unsanitary conditions?
• Is the equipment free of niches, pits, cracks, corrosion, recessed, open seams, gaps inside threads, bolt rivets, protruding ledges, rusting and dead ends?
• Are the enclosures and HMIs designed, constructed, and maintained to ensure food product, water or other liquids do not penetrate or accumulate on the enclosure or interface?
• Is there adequate space between the floor and the equipment body for sanitation?
• Are bearings, gear motors and hydraulic system sealed, guarded, and/or mounted away from the product zone? 
  
  Our 25-point checklist walks through compatibility, compliance, food safety risk and personnel safety.  
  
  Contact a technical sales manager for a plant visit risk review.

With rising costs for energy and labor, there is a continuous need to improve operational efficiency, cut costs, and increase uptimes. One area of improvement is to increase the life and sanitation performance of motors, gear motors and bearings.

In consideration of the TCO (Total Cost of Ownership), some processors choose food safe stainless motors. Encapsulated stainless steel food safety motors, however, are twice the cost of a standard motor. 

The use of painted components are common in food processing plants.  Sanitation is tough on equipment with caustic chemicals spraying at 1000 psi. Once the components chip, there is a risk for the paint chips to enter the food stream. Then corrosion sets in and reduces the life of the component. 

A cost effective, high-performance solution is to start with food grade components and apply the Steel-It brand coating technology using a special application process. Mepaco’s customers have been very satisfied with the result and continue to specify the food grade coating on components for all new projects.

The specialty coating is USDA approved. It blocks corrosion, wear and abrasion and lasts 5+ years in harsh environments.  It is formulated with 316 stainless micro-flakes, making it durable for sanitation and can be subjected to detergents, food acids, alkali, and various chemical agents.

Contact a sales manager for more information about cost saving sanitation.

Here is a quick read on our products and industries that Mepaco serves.

Equipment Products: Cookers, Blenders, Dumpers, Metering Screw Conveyors, Mixers, Pump Feeders, Sanitary Belt Conveyors, Sanitary Design Lifts, Vacuum Stuffers and systems.

Food Manufacturing Industries: Dairy, Meat and Poultry, Pet Food, Plant-Based Foods and Proteins, Processed Foods and RTE, Fruits and Vegetables.

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