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Australian Green Food Production Line: Tubular Conveyor Technology Enables Efficient Expansion

Food processing companies have long searched for a safer, more energy-efficient way to convey products without spillage, breakage, or interruptions due to cleaning and maintenance. While traditional options like belts, buckets, and pneumatic systems were typically used to move larger volumes or bigger products, the introduction of 8″ diameter tubular drag conveyors has made it possible to achieve comparable volumes and pricing to conventional industrial systems.

These tubular drag cable conveyors, which use a coated, flexible stainless-steel cable to gently move product through a sealed tube, can now transport up to 2,000 Ft³ and 80,000 pounds per hour, making it possible to move larger products like whole potatoes and midsized grapefruit, and a variety of foods such as pet food, cereal, nuts, and whole fruit. Many industry professionals are now turning to these higher-volume conveyors due to their improved power usage, safety, product preservation, quality, and production uptime.

These high-capacity tubular drag conveyors are the future of food processing, providing significantly improved power usage, safety, product preservation, and production uptime. Industry professionals are now able to move larger products like whole potatoes and midsized grapefruit, as well as a variety of foods including pet food, cereal, nuts, and whole fruit, all while minimizing spillage, breakage, and interruptions due to cleaning and maintenance.

With the ability to transport up to 2,000 Ft³ and 80,000 pounds per hour, these flexible stainless-steel cable systems offer a cost-effective and energy-efficient alternative to traditional industrial conveyors.

1. Power Consumption
As energy prices continue to increase, there is a growing focus on reducing power usage for conveying materials in the food processing industry. Different types of motors are used within plants, with the high-end pneumatic conveyors requiring large, energy-intensive motors ranging from 20-50 HP or more.

In comparison, mid-range options such as belt conveyors and bucket elevators typically require 25 HP motors to move material at a similar volume. At the low end of the spectrum, 8″ tubular drag cable conveyors utilize a 7.5 HP motor and low-speed discs to efficiently move material. These units can convey a comparable amount of material as traditional options while consuming less energy.

2. Safety
The food industry commonly uses open systems, such as bucket elevators and belt conveyors, which have significant disadvantages related to contamination risks. If left uncovered, these systems can expose products to contaminants and moisture in the surrounding environment. Additionally, open systems can result in product spillage on the plant floor, potentially causing slip and fall hazards if not immediately addressed.

Unlike open systems, closed systems like tubular drag cable conveyors and pneumatic units effectively seal off products from external sources of contamination. The enclosed design of these systems prevents dust from escaping, reducing the risk of unsanitary environments and dust explosions.
Furthermore, the enclosed systems eliminate the potential for slip and fall incidents due to product discharge onto the processing area floor. As a result, these systems create a safer, cleaner, and dust-free work environment. Closed systems, such as tubular drag cable conveyors and pneumatic units, reduce contamination risks in the food industry. These systems ensure clean and sanitary work environments by effectively sealing off products from external sources.

They also eliminate the risk of slip and fall hazards, making them a safer option for processing areas. Additionally, the enclosed design prevents dust from escaping, reducing the risk of dust explosions. With these benefits, closed systems are the ideal choice for maintaining a safe and dust-free work environment.

3. Product Preservation
Enclosed conveyors prevent product loss, which is commonly found in open systems that use belts or buckets. These units have a tube that ensures food products stay securely inside and no powdered product is lost as dust. This can benefit food processors significantly, leading to a surprisingly quick ROI. For example, an international pet food manufacturer processing dog kibble was experiencing excessive product loss due to spillage with a bucket elevator. However, by switching to an 8″ tubular drag cable conveyor, they were able to minimize product spillage and report a 1-year ROI for the system.

4. Product Quality
For delicate products with high value in pristine condition, preserving integrity is paramount. Traditional scooping and pneumatic systems can cause incidental damage, resulting in decreased value. In contrast, tubular cable conveyors offer a gentle solution. These systems use a sealed tube with a coated, flexible stainless-steel drag cable and solid circular discs to slowly move the product without the use of air, preserving its integrity and minimizing waste.

A cereal manufacturer was able to reduce product damage by switching to a high-volume tubular cable conveyor. The benefits are even greater for high-value products like nuts, as a food processor found that damaged almonds sold for only 40 cents a pound, compared to $4 a pound for intact ones. By using a tubular cable conveyor, the processor was able to optimize their sales price while minimizing product damage.

5. Production Uptime
Food processors increasingly expect conveyor systems, like belt conveyors, to be easily cleaned and maintained to reduce production downtime. However, traditional bucket elevators can be challenging to clean, requiring each bucket to be individually removed and thoroughly cleaned, leading to potential residue buildup. Belt conveyors, often cleaned with scrapers, may still require a more thorough cleaning method. Failure to properly clean conveyors can result in contaminated food, leading to lost profits or even harm to consumers.

Even pneumatic conveyors, which are typically seen as easier to clean, may still require manual procedures. In comparison, tubular drag cable conveyors offer a variety of cleaning options, including automated wet cleaning methods, resulting in increased production uptime after every product change. While traditional systems were typically chosen for high-volume output, tubular drag cable units now offer similar capabilities with added advantages in areas such as power consumption, safety, and product quality.

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