We received a request for a maintenance audit on a high volume meat processing line that is a supplier to fast food restaurant chains. The first round of inspection uncovered several maintenance issues:
A Pump Feeder motor kept tripping the breaker and caused constant down-time.
The gearbox bearings were bad and was causing excess loading. The gearbox was replaced which fixed the issue. Reducing down-time for that Pump Feeder.
Mixers on the processing line did not pull sufficient vacuum.
Both mixers had multiple vacuum leaks through cracked welds, worn out seals, incorrect seals and improperly installed seals The seals were replaces and the cracked welds were repaired which allowed the unit to pull required vacuum 2 minutes faster, decreasing cycle times.
Inspection uncovered possible catastrophic failure of the agitators.
Both mixers had agitators with cracked welds. They were repaired during scheduled maintenance.
Vacuum Stuffers were underperforming.
Two stuffers in the processing line were underperforming and producing poor quality product due to lack of vacuum. Both stuffers had worn out pumps that were rebuilt and worn out seals that were replaced. These changes gave the processor a 28% increase in throughput out of the stuffer and better-quality product without air bubbles.
The cost for the maintenance audit, including a detailed report was $2000, plus travel expenses. The result was savings in energy, down-time, batch turnaround and overall increased production. This processor in fact, contracts with Mepaco every six months for a maintenance audit to avoid unplanned delays and to make sure their line is running as efficiently as possible.
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Here's a quick infographic and guide with 7 common parts in food processing equipment that should be in stock for year-end / holiday shut-down maintenance.
1. Motors: Extra motors can prevent unnecessary emergency shut-downs and lost production.
LONG LEAD TIME
2. Agitators: Agitators are custom fabricated to your machine specification, and require longer lead time than typical parts.
3. Cylinders: Make sure you have cylinder back-ups, which can also have long lead times.
4. Safety Switches: Keep extra safety switches in inventory to reduce downtime.
5. Bearings: Mepaco's recommendation for bearings is 1 or 2 back-ups. Check to see if the bearing is a common stock item; if it is not common, plan for longer lead times.
6. Shaft Seals: Plan on 2 - 3 seals per shaft, depending on usage.
7. Gaskets: Gaskets are usually sold in bulk by the foot, check your inventory to make sure you have an ample supply.
If you want to review your parts needs, contact Monica Planasch, Mepaco's Parts Manager, at firstname.lastname@example.org.
With the complex demands in food processing and production, safety, and quality, every component within food equipment is critical. Any machinery with moving parts will utilize bearings. Here are some tips to reduce wear issues and extend bearing life:
There are no major disruptions in our supply chain, but here is a status update with a breakdown of lead times and also recommendations for inventory.
RECOMMENDED SPARE PARTS IN-STOCK*
Air Seal Kits
*Most common spare parts are in-stock, but uncommon parts have a lead time of 2 - 3 weeks.
LONG LEAD TIME PARTS
We are working with required distancing and sanitation to help our customers maintain their production schedule. Our parts and service specialists are on stand-by to support you.
Contact email@example.com or call 920-356-7347.
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