As original equipment manufacturers (OEM) will tell their customers, precision is key to keeping machines running optimally. Bakers need to perform basic maintenance on a regular basis, keep equipment clean and watch for signs of trouble. It’s certainly true for spiral freezers and the conveyors running through them. 

But the best-laid plans can go awry. 

When producers are cranking out product 24/7, parts get out of alignment or machines may start making noises that get ignored. 

Sometimes, untrained workers could fashion a slapdash fix for the problem, which could prove costly.

“We see people using rubber mallets to clamp a belt down, for example, whereas we sell the pliers that are specifically made for that,” said Jeff Fontaine, product manager for Wire Belt Co. “Some people jerry-rig it. It might be good enough to get it up and running, but three weeks or maybe a couple of months down the road, it’s not going to be as you imagine.”

No one wants to imagine equipment failure, unplanned downtime and lost product. But those can be the reality if best practices are not followed. But knowing the potential problems and how to avoid them will save time and money.

Year-round preventative maintenance and making the most of scheduled downtime to check machinery performance is a good place to begin when it comes to keeping freezers and conveyors performing optimally. 

“You want to make sure that the sprockets and other components for that matter are in good shape,” Mr. Fontaine said. “If they need to be replaced, you may need to bite the bullet and buy some replacements. People like saving money so it’s not ideal in the short-term, but ultimately with good equipment and good components on that equipment, it’s going to save you a lot of time and money down the road.”

Bakers need to check the oil in the gear boxes as well as parts throughout the system, said John Bauer, PNA freezer product manager, JBT Corp.

“If you have a drum drive system, make sure wear surfaces are clean and well-maintained and not overly worn,” he said. “You want to make sure you’re recognizing belt and drive chain wear, making these measurements on a regular basis will ensure you don’t run into a catastrophic failure.”

 It’s vital to use the right tools and components made for the equipment.

“A lot of times people say, ‘Can we buy our own sprockets and then use your belt?’ ”  Mr. Fontaine said. “That’s fine, but it’s not going to work as optimally as it would if you bought the sprockets and belt from the same company. The sprockets might not be engineered to match up exactly with that belt.”

Producers considering new equipment should ensure they are getting the best design for their products.

“OEMs design freezers based on operational inputs received from bakers and can also consider growth capabilities and flexibility in the product mix,” said Nicola Menardo, president, TP Food Group — North America. “It is then important that bakeries use, as much as possible, freezers in accordance to the design perimeter defined at freezer design inception. For instance, if bakers use their machines without planning defrosting cycles in the right way, ice buildup in the freezer can potentially be dangerous.”

Predictive maintenance allows producers to keep close tabs on their equipment, giving them a better understanding of how it’s working and if repairs are needed.

“A series of sensors monitor the belt life, the system life, so we help the users know changes over time,” said Jonathan Lasecki, director of engineering, Ashworth Bros. Inc. “Is the belt getting tighter? Is it getting longer? Are bearings starting to get louder? Are temperatures changing? Through this, we’re able to help them see changes or trends over time which allows them to predict failure or changes.”

Mr. Fontaine urged bakers to limit the number of times they splice wire belts, which is replacing a portion of a belt that is damaged with a new piece.

“It’s fine to splice your belt a couple of times, but if you keep doing that continually, you’re weakening it,” he said. “Every time you bend a wire, like a paper clip, it’s going to break eventually. Same thing with stainless steel. When you keep bending these wires, you’re essentially creating weak points.”

This article is an excerpt from the October 2023 issue of Baking & Snack. To read the entire feature on Cooling & Freezing, click here.