While traditional methods of conveying food products, such as belt, bucket, or pneumatic systems, have been selected by many in the industry for their high volumes and ability to handle larger-sized products, tubular drag conveyors offer a safer and more energy-efficient alternative with less spillage, breakage, and maintenance downtime.
With the availability of eight-inch diameter units, these conveyors can now double the volume compared to smaller six-inch units, making them a cost-effective option that can transport larger product sizes such as whole potatoes, midsized grapefruit, and even pet food, cereal, nuts, and whole fruit. Featuring a sealed tube and a coated, flexible stainless steel drag cable, these conveyors use solid circular discs (flights) to gently push products through without the need for air.
Their versatility and gentle transport make them ideal for delicate and precise blends of various food types, making them a popular choice in the food processing industry.
1. Power Consumption
As the cost of energy continues to rise, food manufacturers are increasingly focused on lowering the power needed to transport materials. Motors used for conveying large amounts of food within a facility can have vastly different power requirements. Pneumatic conveyors, for example, use air pressure to move products quickly through an enclosed line, requiring larger, high-powered motors of up to 20-50HP to operate fans, blowers, and rotary valves.
In comparison, belt conveyors and bucket elevators, which form a closed loop with a drive pulley, typically consume around 25 HP. Eight-inch tubular drag cable conveyors use even less power, only requiring a 7.5HP motor to move a comparable volume of materials, thanks to their low-speed, energy-saving method of pulling solid discs through a loop. These discs are larger and more plentiful on eight-inch units, allowing them to transport the same amount of material as traditional belts, buckets, or pneumatic units.
2. Safety
The use of open systems such as bucket elevators and belt conveyors is prevalent in the food industry. However, these systems have significant downsides as they can easily expose products to contaminants and moisture from the surrounding environment.
Moreover, they also pose a potential slip-and-fall hazard due to product spillage on the plant floor. In contrast, closed systems like tubular drag cable conveyors and pneumatic units effectively safeguard products from external contamination and dust exposure. These enclosed systems ensure a dust-free and hygienic work environment, reducing the risk of slip and fall incidents and dust explosions.
3. Product Preservation
The use of enclosed conveyors prevents the loss of products often associated with open systems, such as belt or bucket units. With the product safely contained within the enclosed tube, there is no risk of it falling out, and no powdered product is lost in the form of escaped dust.
This can greatly benefit food processors in terms of profitability, with potential for a surprisingly quick ROI. For example, a leading international pet food manufacturer saw significant reductions in product loss and reported a one-year ROI after switching from a bucket elevator to an eight-inch tubular drag cable conveyor.
4. Product Quality
When handling delicate or high-value products, it is crucial to maintain their integrity. However, traditional methods such as scooping or dumping from buckets can result in incidental damage, decreasing the value of the product. Pneumatic systems, with their high-speed conveyance through tubing and turns, can also cause damage due to the rough mechanical action. In contrast, tubular cable conveyors offer a gentler solution.
By using a sealed tube and a coated, flexible stainless-steel drag cable with circular discs, the product is pushed at a low speed without the use of air, preserving its integrity and reducing waste. A cereal manufacturer saw a significant decrease in product damage after implementing a high-volume tubular cable conveyor. This is especially important for high-value products like nuts, where even slight damage can greatly affect their market price. One food processor selling almonds noticed a price difference of $3.60 per pound when damaged versus whole and undamaged.
5. Production Uptime
Food processors expect conveyor systems to be easy to clean and maintain, which can reduce production downtime. However, some systems, like bucket elevators, can be challenging to clean, causing potential contamination and lost profit if not cleaned properly. This can also lead to damage to brand reputation, costly recalls, and even liability. In contrast, tubular drag cable conveyor systems offer more options for efficient and thorough cleaning, such as brush boxes, air knives, sponges, and even automated wet cleaning.
By incorporating more automated cleaning methods, food processors can save time and increase production uptime, while still achieving high-volume output and other advantages. Although traditional systems, such as belts, bucket, or pneumatic, may be more familiar to processors, the benefits of tubular drag cable systems make them a more desirable option for higher capacity needs.