Larger 8-Inch Tubular Drag Conveyors: Boosting Profitability and Volume in Food Packaging Systems
The availability of 8-inch diameter tubular drag conveyors has revolutionized material handling in food packaging systems, effectively doubling the capacity of smaller 6-inch units. This increase in size offers comparable volumes and pricing to conventional industrial conveyors, while also enabling the transport of much larger products than previously possible.
Increased Capacity and Versatility
These 8-inch tubular drag cable conveyors can move up to 2,000 cubic feet and 80,000 pounds per hour, depending on the bulk density of materials. They can handle large products, such as whole potatoes and midsized grapefruit, and are now being used to convey a variety of food products, including pet food, cereal, nuts, and even whole fruit.
The conveyors operate by gently moving product through a sealed tube using a flexible, coated stainless-steel drag cable, which is pulled through a loop. Solid circular discs (flights) attached to the cable push the product through the tube without the need for air. This system excels in transporting delicate, precisely blended products across various layouts and configurations.
Today, food processing and packaging professionals are increasingly turning to these higher-volume tubular drag conveyors to enhance power efficiency, safety, product preservation, product quality, and overall production uptime.
Power Consumption and Energy Efficiency
As energy costs rise, food packagers are more focused on reducing the power needed to convey materials. Within production plants, conveyors vary widely in their energy consumption, particularly when moving large volumes of food products.
At the high end of the spectrum are pneumatic conveyors, which use air pressure to move products at high velocities through enclosed lines. These systems often require large, energy-hungry motors, ranging from 20 to 50 HP or more, to run fans, blowers, and rotary valves.
Belt conveyors and bucket elevators are more energy-efficient alternatives, typically using 25 HP motors to move similar volumes. These systems rely on continuous belts or chains to transport materials, but they still require considerable power.
In contrast, 8-inch tubular drag cable conveyors only need a 7.5 HP motor to move comparable volumes of material. By pulling solid discs through the tube at low speeds, they consume less energy than traditional systems while achieving similar throughput. The larger size and increased number of discs in the 8-inch units allow them to match the capacity of traditional belt, bucket, or pneumatic systems.
Safety and Cleanliness
Closed systems like tubular drag conveyors and pneumatic units are highly effective in preventing contamination, as they completely seal the product from the outside environment. This enclosed design not only keeps the product safe but also ensures that no dust escapes, avoiding potential contamination and creating a cleaner, safer work environment. It also reduces the risk of dust explosions, particularly when dealing with powdered food materials, and minimizes slip-and-fall incidents caused by spilled product on the floor.
Product Preservation and Quality
Enclosed tubular conveyors offer significant benefits in product preservation. Because the system is sealed, there is no risk of product loss or dust escape. The products stay within the tube, reducing waste and improving efficiency. This system is especially valuable in the food industry, where minimizing product loss can have a direct impact on profitability.
For example, a major international pet food manufacturer switched to an 8-inch tubular drag conveyor for transporting dog kibble, minimizing product spillage and achieving a return on investment (ROI) in just one year.
Additionally, tubular drag conveyors are gentler on delicate products such as cereal and nuts, preserving their integrity and preventing damage during transport. For high-value products, this preservation of quality can significantly increase the selling price.
For instance, a food processor dealing with almonds saw the price per pound of whole, undamaged almonds rise from $0.40 to $4.00. By switching to tubular drag conveyors, the processor minimized product damage and maximized revenue.
Production Uptime
Food processors are increasingly seeking conveyor systems that are easy to clean and maintain, as improper cleaning can result in product contamination, leading to discarded batches, recalls, or even liability.
Tubular drag conveyor systems offer several options for both dry and wet cleaning, including brush boxes, urethane wipers, air knives, inline sponges, bristle brushes, and even automated Clean-In-Place (CIP) systems. These automated cleaning methods can significantly reduce downtime by cutting cleaning time compared to traditional manual methods.
For example, using inline cleaning tools or CIP wet cleaning can result in hours of additional production uptime after every product change, a crucial advantage for food processors who need to maximize production efficiency.
Conclusion
By adopting 8-inch tubular drag cable conveyors, food processors and packagers can match the high-volume output of traditional conveyor systems while benefiting from lower power consumption, enhanced safety, better product preservation and quality, and increased production uptime. These advantages translate into higher profitability, a quicker return on investment, and greater overall efficiency in food processing and packaging operations.