Cleaning the Gigantic Conveyors: Not So Simple

The right materials and the ideal design are necessary for an efficient and thorough cleaning of the conveying system, to achieve compliance to sanitation regulation.

FREMONT, CA: Even tiny tidbits of residual food particles on the conveyor belt cause a breach in food quality. The accumulation of food product in any size encourages the bacteria to develop and grow on the conveyor belt. This is not only harmful to the conveyor but also contributes to the spoilage of food products.

To prevent the microbial contamination and trace the origin of the reaction to the source DNA mapping is utilized. DNA mapping helps to avoid the situation before drastic measures like recall and disposal of the food products need to be enforced that not only cause losses to the manufacturer but also taint the reputation of the enterprise. 

Several changes to the laws have been made to exert excess pressure on the manufacturers to provide equal importance to sanitation. The FDA Food Safety Modernization Act (FSMA) are rigid on the transformation of food companies by transferring the attention from responding to the breaches and contamination to being proactive and preventing the contamination from occurring in the first place.

Cleanliness is the most important quality that food processors should prioritize, especially when the factories are mechanized. In concern to conveyors, the long, complicated system which is in constant motion and deals with most food products needs to be cleaned regularly.

The stainless steel conveyor belt is utilized as the cleanability of the system is much easier. The majority of the food-grade conveyors available in the market at present intentionally manufactured for direct product contact are made up of stainless steel. It does not only resist microbial growth and corrosion, especially when coated with mild steel.

A key factor that needs to be paid attention is the finishing of the steel. As varied finishes react differently when it comes to corrosion, some increases the risk with chemical washes and 316-grade stainless steel resists better than a 304. A rotary polish finish makes the surface appear smoother and completely avoids the growth of microbes. However, in the case of sanitation, the conveyor alone made of stainless steel will affect no difference.

While a sanitary conveyor is designed, several pointers should be given extra attention to avoid the accumulation of product residues. Welded, rounded frames are to be attached with minimal fasteners in the food zones.

The primary spot for sanitation awareness in a conveyor system is the product contact surface, may it be a belt, pan, or even tub that transports the product. The hot-spot in the system is where the choice of the material and the finish makes the most difference. Features in the right combinations make the product conveyance efficient and enhance compatibility with the required sanitation method. Modular plastic, fabric, and solid plastic are the ideal materials for the conveyor belts.

Fabric belts are vulnerable to fraying; adding to the list of sanitation issues, but it can be avoided by utilizing the fabric belts which are encapsulated at the edges. For processes with high water activity, such as chicken, poultry, and other meats where draining of the water is necessary, modular plastic is used. An ideal conveyor material is the urethane belt; it eliminates crevices and is relatively simple to disengage and clean.

From a hygiene standpoint, the mode of powering the conveyor is equally essential when compared to the product contact surfaces. The positioning, type of motors, and connections to the belt have to be configured to support maximized cleanability.

The options that exist for power transmission even though much choice isn’t available are standalone motors, gear motors, and drum motors. Although separate engines and gearboxes are available for a much lesser price, the motors each have a practical advantage that supports the cleaning process. But, Gear motors and drum motors have the upper hand over the motors available in standardized specifications. The enclosed feature of the motors makes wash downs much easier.

The components of power transmission also pose another risk of contamination; the oil used for the lubrication of the parts. Most manufacturers utilize food-grade lubricants for the same purpose; it avoids the risks instead of eliminating it. The ultimate solution to prevent the contamination from motors, gearbox, and oil is to adopt vibratory conveyors that run on oil-free vibrating motors.

The tube conveyors, although efficient present a somewhat unique challenge in the case of sanitation. The enclosed interiors which are used to transport powders or bulky solids are tough to access. With disks or pressurized air is used to move the product, an additional issue of cleaning the forward-facing surfaces of the disks. But when conveying is carried out with a physical action means that cleaning can also be done with the same.

To tackle this issue, a urethane “pig” is used; the pig, when dragged through the tubes of the conveyor, cleans the surface out. The cleaning should be done after every round and before changing the product. A routine is to be set, and once in seven to ten days, thorough cleaning should be carried out as well with a sponge-based attachment.

Maintaining the cleanliness in the conveyors is no joke, especially considering the size and the complex mechanisms of the machine. Equipping the team with the ideal technology and products will make the job easier, and many efficiencies in handling can be obtained.