Family of Brands

The Grote Company Family of Brands has provided food processing equipment, parts, and services for decades. We work together to give food manufacturers a team of experts dedicated to providing more complete solutions and unwavering support.

         ProFab   
Where to Buy In the News

Resource Category: Blog

A complete PFI tote dumper system ready for installation.

How Much Does a Tote Dumper Cost?

Written by Howard on .

Bulk material handling is critical to keeping food processing lines running consistently and efficiently. This is especially true for dumpers that introduce large volumes of product from large crates, vats, and totes to the line.

Several dumper design and model features combine to affect the initial purchase price and total cost of ownership. Read on to learn more about these factors.

THE IMPORTANT ROLE OF FOOD DUMPERS IN FOOD PROCESSING 

Tote dumpers, or vat dumpers, play a crucial role in food processing plants by unloading large amounts of bulk product to the production line efficiently and safely. They are used in many different industries and applications, including:

  • Bakery
  • Cereal production
  • Dairy
  • Fruits and vegetables
  • Frozen foods
  • Meat processing
  • Nuts
  • Pasta
  • Pet food
  • Snack foods

Dumpers increase efficiency and throughput while improving worker safety. They’re essential for high-volume food processing operations to maintain consistent product flow. 

PFI offers dumper systems designed for optimal product handling, flexible configurations, and safe operation. Our dumpers can operate as standalone units or integrate easily with other bulk handling and conveyance machinery for a cohesive and efficient production line.

FACTORS THAT IMPACT TOTE DUMPER COST 

A combination of design, materials, and operational requirements influences the cost of tote dumpers. Although these individual components and options may increase the cost by small amounts, the combined effect can significantly impact the overall price. 

Materials and Sanitation Level: Tote dumpers were once available in mild and stainless steel. Stainless steel has become the industry standard due to its sanitary benefits and durability. PFI offers stainless steel RTE models that meet crucial sanitation standards.

Capacity and Size: Dumper load size can range in weight and dimensions to accommodate product containers. Common dumper capacity ranges from 1,500-3,000 lbs. Larger and heavy-duty load models are priced higher. 

Stages and Discharge Height: Depending on the application’s needs, the dumper’s design can include single or dual-stage tilting action at various discharge heights. 

Customizations and Safety Features: Specific machine components, such as guarding and safety features, contribute to the cost. Customizations like bag catchers, pallet retention systems, and other specialized features add value but increase the overall cost even more.

ADDITIONAL DUMPER COST CONSIDERATIONS

 

A PFI tote dumper handling walnuts

The purchase price is just the initial factor to consider. Installation, maintenance, and aftermarket parts also contribute to the total cost of ownership (TCO) over the machine’s lifetime.

Installation and Training: Vat dumper installation is a separate cost. However, free training at installation is included to ensure operators know how to use the equipment effectively and safely.

Maintenance and Operational Costs: Tote dumpers are generally low maintenance. However, components like hydraulic cylinders, valves, hoses, and fittings may need occasional replacement or rebuilding. These costs combined can add up to a few thousand dollars annually. The machines run on hydraulics and do not require much electricity. The overall energy consumption depends on the dumper’s run time and the number in use.

Replacement Hydraulic Cylinders: Hydraulic cylinders and their power units keep dumpers in operation. Cylinders require regular replacement to avoid a decline in performance. PFI offers 4-inch bore replacement hydraulic cylinders for our machines and other OEMs, as well as a rebuild service to extend the life of existing cylinders. 

AVERAGE PRICE RANGES 

Tote dumpers generally cost between $75,000 and $80,000, depending on the specific model and its configurations. Adding custom features or opting for a heavy-duty model with a 5:1 safety factor can increase the cost to $250,000. While these higher-end options are less common, they are available for operations that require enhanced safety or capacity.

MAXIMIZE YOUR TOTE DUMPER INVESTMENT 

Selecting the right tote dumper is crucial for efficient production, worker safety, and cost control. PFI offers expert solutions tailored to meet the unique needs of food processing operations. We use high-quality materials and proven design options that allow for decades of flawless operation.

Click below to explore our equipment and find the right fit for your operation.

View Our Tote Dumpers

Chicken nuggets traveling down a PFI Laning Vibratory Conveyor.

How to Choose the Right Conveyor for Meat Processing

Written by Kimberly on .

Meat processing facilities face several challenges in their daily operations. Ensuring food safety, maintaining high throughput, and adhering to regulatory standards can be daunting tasks. Processing different types of meat with unique handling and temperature requirements makes this even harder. 

Finding a conveyor system that meets all these demands while being cost-effective and easy to maintain is challenging. Fortunately, there are solutions designed to address these specific needs. Read on to learn more about choosing the right meat-processing conveyor.

CRITICAL CONVEYOR SELECTION FACTORS 

Conveyors are essential in maintaining food safety, sanitation, and product quality during the primary (butchery) and secondary (dicing/portioning) processing stages through packaging. 

Choosing a meat processing conveyor involves careful consideration of several different challenges, including:

Hygiene Standards and Sanitation Requirements

Maintaining impeccable hygiene and sanitation standards is crucial for ensuring food safety and operational efficiency in meat processing facilities. Here’s how compliant conveyor equipment plays a pivotal role:

  • Stringent Standards Compliance: Food-grade conveyors must meet rigorous hygiene standards set by organizations like the American Meat Institute (AMI) and the USDA.
  • Regulatory Adherence: Facilities must comply with HACCP and FDA regulations to minimize contamination risks and uphold product quality.
  • Minimizing Cross-Contamination: Conveyor systems designed with accessibility and ease of cleaning in mind help mitigate cross-contamination risks during processing.
  • Operational Efficiency: Adhering to these regulations contributes to safer and more efficient operations, avoiding legal and financial repercussions that can harm a company’s reputation.

By prioritizing hygiene and sanitation in equipment selection, meat processing facilities can optimize efficiency, reduce costs, and ensure the highest standards of food safety.

Type of Meat and Application/Process

The type of meat plays a critical role in selecting the right conveyor system. For example, ground meat requires different handling than hot dogs or frozen chicken tenders. Raw meat must be kept at specific temperatures for safety reasons.

Product Integrity and Yield

It’s essential to maintain high throughput capacities while preserving product integrity. Conveyance systems must prioritize gentle handling and minimal product damage. And beyond regulatory requirements, food safety practices significantly influence product quality and yield and operational efficiency.

  • Extended Product Life: Effective sanitation practices prevent bacterial growth, extending product shelf life and reducing waste in processing.
  • Minimizing Waste: Conveyors can be equipped with return lines that send stray bits back to previous processes or fitted with catch pans and accessories designed to capture them.

Throughput Capacity: Capacity & Uptime

Meat moves quickly from farm to slaughter to processing—poultry moves even faster. Conveyors need to be durable and reliable to run consistently with little maintenance. This ensures total uptime in a fast-paced meat processing environment.

Full Solution vs. Individual Conveyor

It is important for meat processing facilities to choose between a complete conveyor system and individual conveyors. A complete system offers seamless integration and enhanced automation, improving overall efficiency. On the other hand, individual conveyors provide more customization options to meet specific processing requirements.

Look at the entire process. This includes conveying equipment and as much automation upstream and downstream as possible. Options or equipment can automate additional processes. Services to consider are:

  • Engineering layout design
  • Expert opinions and advice
  • FAT/testing availability
  • Installation
  • Millwright services

Utilizing OEM connections can create complete process systems through a one-stop shop. This approach is typically reserved for engineering firms and dealer/distributors who manage entire projects.

Material and Design Considerations

Selecting the right materials and designs for a conveyor system is crucial in meat processing. Conveyors must be made from materials resistant to corrosion and bacteria growth to ensure easy cleaning and sanitation. These materials must also withstand cleaning chemicals used in the process.

Designs must allow easy access for maintenance and cleaning. This reduces downtime and increases overall efficiency. Easy-to-clean equipment maintains hygiene standards and ensures smooth conveyor system operation.

TYPES OF PFI MEAT PROCESSING CONVEYORS

Sanitary conveyor design is critical for meat processing

PFI offers a range of conveyor systems designed specifically for meat processing applications. All of our conveyors meet exceptional sanitation standards and comply with industry regulations.

Belt Conveyors

Belt conveyors are popular in meat processing due to their versatility, long-distance conveying, and low initial cost. 

Bulk Handling Equipment

Bulk handling on the raw and kitchen sides uses dumpers to move large volumes of meat efficiently. These dumpers provide smooth and safe transfers while maintaining productivity. Their flexible and easy-to-clean design meets high sanitation standards.

Dumpers and Screw Augers

Dumpers efficiently unload bulk product totes to quickly introduce product to the processing line. They handle products smoothly to minimize contamination. Screw augers precisely move bulk materials without spillage or loss, while maintaining product temperature and integrity.

Both equipment types improve workflow and uphold sanitation standards. Their design allows easy cleaning and flexibility, crucial for productivity and safety in processing environments.

Bucket Elevators

Bucket elevators are perfect for moving products to different heights. They are ideal for elevating products to tall processes (or equipment), including slicing/dicing/portioning/grinding and packaging. 

Vibratory Conveyors

Vibratory conveyors provide gentle product handling and are typically used in frozen and processed meat lines feeding into packaging lines. They ensure efficient and sanitary product transfer.

These conveyors maintain product integrity and reduce the risk of cross-contamination. They offer precise control over product flow, making them ideal for applications requiring careful handling and distribution.

INNOVATIVE MEAT PROCESSING CONVEYOR SOLUTIONS

PFI engineers work on a meat processing conveyor solution.

Choosing a conveyor system that prioritizes safety, efficiency, and adherence to industry standards is essential. At PFI, we design custom conveyors that meet high sanitation standards and adhere to regulatory guidelines. 

Click below to discover how PFI can optimize your meat processing operation with innovative conveyor solutions.

View Our Meat Processing Solutions

A PFI bakery conveyor transporting individual pancakes onto a secondary conveyor.

Choosing the Right Bakery Conveyor for Your Application

Written by Kimberly on .

Bakeries are very fast-paced environments that process a variety of delicate products prone to damage. Soft bread, bars, and packaged cookies are particularly vulnerable when mishandled.

Conveyors are vital in minimizing damage, adapting to diverse product mixes, and maintaining efficient production flow. However, selecting the right one can be challenging due to numerous considerations.

Read on to learn how to choose the right bakery conveyor for your operations.

ESSENTIAL CRITERIA FOR SELECTING THE RIGHT CONVEYOR 

Evaluating conveyors requires a thorough assessment of several critical factors. These include:

Product Type & Mix

Bakery products change significantly throughout production – from ingredients to raw dough to a prepared product to a baked product to packaging. It’s essential to consider where a conveyor will be to determine the right solution, belt, and components.

Conveying systems need to adapt to not just one product, but many. Adjusting to different products and recipes is important for maintaining productivity and meeting changing consumer demands. A versatile conveyor system can help streamline production by allowing seamless transitions between various product types without compromising efficiency or quality.

Production Volume & Uptime

The dimensions of the conveyor will need to accommodate the flow of products based on your production capacity. For example, a wider belt may be necessary for higher volumes to ensure efficient processing and minimal downtime.

High performance and minimal downtime are essential for maintaining productivity in fast-paced bakery processing environments. Choosing a reliable conveyor system that consistently delivers on uptime can help ensure smooth operations and reduce the risk of costly disruptions to your production schedule.

Sanitation Requirements

A sanitary design avoids harmful bacteria and allergens such as nuts and gluten. Conveyors must have easy-to-clean surfaces and components to minimize contamination risks and ensure compliance with BEMA design standards.

It is imperative to opt for materials and designs that are food-safe, resistant to corrosion, and capable of preventing bacterial growth. These features allow for quick and thorough cleaning to maintain food safety.

Space Constraints

Bakeries with limited space may require elevating solutions or creative configurations to maximize footprint utilization. For instance, a Curveyor can help meet production needs in confined spaces by navigating around processing equipment, facility walls, columns, and doorways.

The Curveyor maximizes a food plant's footprint by facilitating product flow in the most challenging layouts.

Tight Transfers and Integrations

Proper connections between equipment prevent product damage during handling and maintain overall efficiency throughout the processing line. Conveyor system designs often incorporate retractors or other specialized components at various production stages for smooth transitions.

Maintenance

Regular maintenance checks ensure minimal downtime and efficient production. This includes inspecting belts for wear, lubricating moving parts as needed, and addressing any issues promptly before they escalate into more significant problems that could disrupt operations.

Ease of Cleaning

Easy-to-clean machines reduce downtime and contamination risks by allowing quick washdowns with minimal effort. Features such as positive drive belts, modular belt designs, and easily accessible components can all contribute to more efficient cleaning processes.

Choosing the right conveyor system is crucial for your bakery’s success. Careful consideration of these factors will help you find the right equipment that boosts efficiency, quality, and profits.

TYPES OF FOOD PROCESSING CONVEYORS 

At PFI, we offer a wide range of conveyor systems designed specifically for bakery processing applications. Each one offers unique benefits that make it suitable for different stages of production or particular product types:

Belt Conveyors

We equip our most common bakery conveyor solution with positive drive belts. These help with sanitation because they have fewer moving parts, smooth surfaces, and less horsepower. They also feature tight transfers to prevent damage during handling.

Our belt conveyors are ideal for many bakery processing applications, including:

  • Raw dough (buns, biscuits, bread): The Eleveyor and PURlift (commonly referred to as a “dough lift”) is a vertical lift conveyor with a positive drive that efficiently elevates raw dough 90 degrees to a chunker or divider. Positive-drive flat belts also transfer raw dough between equipment.

The Troughveyor excels at transferring large volumes across long distances with no loss. It features an open frame that allows for fast and thorough cleaning.

  • Bars/Packaged Bakery Items: The Curveyor uses specialized timing sequences to orient and alight bars, individual pancakes, and other bakery items for packaging purposes.

Modular belt conveyors have an open design that enhances airflow for faster product cooling. They efficiently manage items at different temperatures, including those needing to be cooled after par-baking.

Retractors and Curveyors help to ensure the alignment, positioning, and orientation of bakery items during the processing or packaging stages. This maintains product quality, prevents damage, and facilitates efficient production workflows.

An aerial view of an entire pancake processing line

Bucket and Incline Conveyors

Eleveyor and PURlift conveyors are very common in the baking industry. They can elevate dough or baked goods to mixers, dividers/chunkers, ovens, tall equipment, or a platform/mezzanine.

Vibratory Conveyors

They’re mainly used for sprinkling toppings over products or mixing/blending recipes of granola-type products. They provide gentle handling and precise control over the distribution process, ensuring consistent results every time.

All PFI conveyors meet exceptional sanitation standards. They comply with various regulations to maintain cleanliness and safety in bakery processing environments.

EVALUATING CONVEYOR OPTIONS AND MAKING THE RIGHT PURCHASE DECISION 

Choosing the right bakery conveyor system is not as easy as it may seem. Every bakery has unique needs and challenges that influence this decision. Understanding these specifics is crucial to finding the perfect fit.

Choosing a supplier that can provide customized solutions tailored to your unique requirements is essential. Look for an experienced partner with engineering expertise to design innovative solutions and a willingness to meet your exact needs.

Additionally, ensure you opt for features like belt scrapers to remove residue or belt lifts and Clean-in-Place (CIP) systems for cleaning. These enhancements improve sanitation efficiency and reduce downtime. Efficient cleaning processes are crucial for maintaining high production standards.

PFI’s experienced team works closely with clients to design and manufacture conveyors that meet their exact specifications. Our comprehensive approach ensures optimal conveyor selection for each unique bakery operation.

OPTIMIZE YOUR BAKERY PRODUCTION LINE WITH PFI CONVEYORS 

Downtime, product loss, and recalls are very expensive. Loss of reputation or contracts often leads to long-term market share erosion and a competitive disadvantage. This is why selecting the right bakery conveyor solutions is crucial to ensuring efficiency, product safety, and regulatory compliance.

PFI stands out as a leader in providing bakery conveyor solutions. Our expert team designs and manufactures conveyors that meet the highest standards of sanitation and efficiency.

Click below to explore our equipment and discover how we can help optimize your processing line.

View Our Bakery Solutions

Common Vibratory Conveyor Applications

Written by Howard on .

Vibratory conveyors are essential tools in the food processing industry. They use controlled vibrations to gently move products along the production line–and so much more. 

Vibratory conveyors offer food processing applications beyond basic transportation. This adaptability allows for customization with various pans, accommodating different products and uses. These value-added features make vibratory conveyors valuable tools for optimizing multiple processes, boosting productivity, and maintaining stringent quality standards.

Screening

One key value-added application of vibratory conveyors is screening. Utilizing a perforated pan, these conveyors efficiently remove unwanted materials such as small or broken pieces, fines, and other debris that can impact product quality. 

The vibrations cause these unwanted particles to fall through the perforations, leaving behind a consistent, high-quality end product. This automated process improves the final product and reduces the need for manual sorting, leading to significant cost savings and improved overall efficiency in the production line.

Dewatering/Shaking

Vibratory conveyors (shakers) effectively remove excess water from wet products. As the product moves across a perforated screen, the vibrations drain water. This is especially useful for fruits and vegetables after washing, preparing them for packaging or further processing. This drying process prevents spoilage, maintains quality, and reduces contamination risk. It also improves efficiency in the following steps.

Laning

Aligning and orienting products is crucial for packaging or further processing in food operations. Vibratory conveyors with lanes guide products into specific positions, ensuring correct alignment for downstream operations. This setup increases efficiency and reduces the risk of misaligned products, jams, and damage. As a result, throughput improves, and waste decreases.

A vibratory food conveyor system made of stainless steel trays keeps chicken tenders sanitary.

Sorting/Grading

Vibratory conveyors with adjustable screens or specialized sorting mechanisms can automate the sorting and grading process. 

As products move across a series of perforated pans with different-sized holes, the vibrations cause them to fall through the appropriate holes, separating them based on size. This automated process ensures accurate and consistent product grading. It reduces the need for manual labor and minimizes the risk of human error.

A food-grade conveyor sizes pieces of chewing gum.

Spreading

Maintaining a uniform distribution of products is crucial for many food processing operations, such as drying, coating, or inspection. Vibratory conveyors can be designed with spreading mechanisms that ensure an even layer of product across the entire width of the conveyor belt. This consistent flow improves throughput and reduces waste. It provides uniform processing, leading to better product quality and consistency.

Feeding

Vibratory conveyors are also used to control the product flow from bulk handling systems into downstream processes. The controlled vibration ensures a steady and consistent feed, preventing overfeeding or underfeeding that could disrupt production. 

Mixing & Blending

One application of vibratory feeders is mixing and blending. Precise metering of ingredients is essential for maintaining accurate recipe formulations and consistent product quality.

Candy is mixed, blended, and sorted on a vibratory conveyor

WHY VIBRATORY CONVEYORS ARE THE IDEAL SOLUTION 

Vibratory conveyors offer high throughput and rapid movement of large product volumes, which increases production levels. Their low maintenance requirements also make them ideal for minimizing downtime and reducing the total cost of ownership.

Vibratory conveyors are particularly well-suited for additional food processing applications due to several factors. 

Increased Performance Without Additional Equipment

Customizable pans on vibratory conveyors and feeders can perform various applications, eliminating the need for multiple machines. This value-added approach allows for the simultaneous conveyance and manipulation of products while improving overall efficiency. Food processors enjoy reduced capital budget, line footprint, and operations and maintenance.

Sanitation & Food Safety

Vibratory conveyor pan angles eliminate contamination areas.Maintaining hygiene and product integrity is paramount in food processing. Their sanitary design meets these stringent requirements. One-piece, smooth pans with angled side edges eliminate areas where a product can build up or become contaminated.

Vibratory conveyors are designed with sanitation in mind. Compared to belt conveyors, the minimal number of moving parts reduces potential contamination points. Their open-access frames also allow for quick and easy cleaning, maintenance, and swab testing. This ensures that production can resume promptly after these procedures.

Gentle Handling Equals Optimal Product Integrity 

The gentle vibration of these conveyors helps maintain product integrity. The precise vibration frequency is carefully calibrated to move products without causing damage (e.g., breakage or seasoning loss). This gentle handling is crucial for preserving the quality and appearance of delicate or fragile products.

The continuous movement prevents slippery products like meat from remaining stationary for extended periods. This helps avoid unsafe temperature zones caused by friction or production stoppages.

SEAMLESS INTEGRATION INTO FOOD PROCESSING LINES 

Due to their adaptable design, integrating vibratory conveyors into existing food processing lines is straightforward. Depending on the specific application, they can be easily installed at various points in the line. 

Whether transporting ingredients between processing stages, sorting products by size, or dewatering washed vegetables, vibratory conveyors can be customized to fit the unique needs of each operation. They can handle a wide range of food products, from dry snacks and pet food to soft bakery items and meats, making them a valuable asset for any food processing facility.

PFI: YOUR PARTNER IN VIBRATORY CONVEYOR SOLUTIONS 

PFI is your trusted expert in vibratory conveying solutions for the food processing industry. We design and build custom sanitary systems that gently handle your products, clean easily, and offer long-lasting value. Popular models include the versatile VFII, the precise EDF feeder, and the efficient MAGNEflex.

Food safety is our top priority. We use stainless steel and minimal moving parts, reducing maintenance needs and improving hygiene. Our systems ensure optimal product handling to minimize product damage regardless of the food type. We offer flexible configurations and work closely with customers to integrate our equipment into existing processes.

PFI boasts decades of experience and a commitment to quality. We will help you find the perfect vibratory solution to optimize your production line and achieve energy efficiency. Our expertise and commitment to quality ensure a reliable and efficient system that enhances your production.

Click below to explore how our vibratory conveyor solutions can enhance your food processing line.

View Our Vibratory Conveyors

A PFI vibratory conveyor grading shoestring fries

How Much Does a Vibratory Conveyor Cost?

Written by Howard on .

Vibratory conveyors are essential machines in the food processing industry. These powerful workhorses move, sort, grade, and handle various products effortlessly. However, as with any large equipment purchase, it’s vital to understand the cost implications.

Several important factors influence the overall price of a vibratory conveyor. Understanding them will help you budget and make a more informed decision. Read on to learn more about vibratory conveyor costs and what drives pricing variations.

FACTORS IMPACTING VIBRATORY CONVEYOR COST 

Vibratory conveyors come in many variations to suit specific applications in the food industry. The type and complexity of the solution you need will greatly influence the overall cost.

Drive Type

Electromagnetic and mechanical vibratory conveyors use different operating mechanisms, directly affecting their cost. Electromagnetic conveyors often have a higher initial price tag but may be more energy-efficient over time.

Solution Type

A simple conveyor setup has a different price point from a more complex vibratory one. These complexities drive the most price increases due to the additional components and design time. The solution choice hinges on your project scope and the tasks you need the system to accomplish.

Value-Added Applications

Vibratory conveyors can perform various functions beyond basic conveying, but each application comes with its own cost implications:

  • Feeding: While basic feeding typically doesn’t require significant design changes, custom controls or hoppers may be necessary to ensure a consistent and metered flow.
  • Screening: Specialized screens with various mesh sizes and configurations are integrated into the conveyor bed to separate particles by size or remove foreign objects. A separate takeaway conveyor is often included to remove and collect oversized or unwanted materials (“takeaway”).
  • Dewatering: Removing excess moisture or liquid requires specially designed pans or decks with drainage holes or slots. A collection pan or trough beneath the conveyor may be necessary to catch and redirect the drained liquid.
  • Laning: Dividers and guide rails are added to the pan to create multiple product lanes on a single conveyor. More complex configurations may involve multiple vertically tiered conveyors, each with its own motor and controls.
  • Grading: Specialized pans with varying slopes, multiple tiers, or a combination of both are used to sort products by size or quality. This differs from laning, which typically uses a single pan with dividers.
  • Spreading: Even product distribution across the conveyor often requires custom-designed pans or strategic placement of additional vibration motors.

A PFI laning vibratory conveyor moving processed chicken nuggets.

System Complexity & Integrations

The total cost of your vibratory conveyor system depends on its overall complexity. A system with multiple conveyors and supporting equipment like platforms or stairs will naturally be more expensive than a single, standalone conveyor.

Integrating your vibratory conveyor with existing equipment or other processing lines adds another layer of complexity and cost. For example, transitioning from a wide conveyor to a narrow one, merging multiple lines into one, or elevating a product from floor to a platform requires additional components and engineering. 

Customizations

Any modifications or integrations beyond a standard conveyor setup will alter the price. Common customizations might include changes in shape or size or the addition of specialized discharge chutes.

Size

The physical size of the conveyor—length, width, depth, and the overall number of conveyors needed—all impact costs. A longer or wider conveyor or a multi-conveyor system will naturally be more expensive.

Electrical Controls

Simple controls are less expensive than centralized systems. However, centralized controls for multi-conveyor setups can improve safety, boost efficiency, and reduce downtime. These improvements will ultimately impact your bottom line.

Sanitary Design

RTE (ready-to-eat) and USDA-compliant sanitary conveyors follow strict material and construction standards. Due to the use of stainless steel and other specialized design elements, they are more expensive to manufacture. However, sanitary conveyors are vital in preventing costly product recalls.

Quality/Durability

Investing in high-quality materials and construction pays dividends in the long run. A well-built conveyor will have fewer maintenance problems and last much longer, resulting in a better return on investment over time.

Expertise and Support

Choosing a vibratory conveyor supplier with extensive experience in the food processing industry is crucial. A knowledgeable manufacturer like PFI understands the unique challenges and regulatory requirements of food production. 

We can guide you in selecting the right solution, ensuring it meets all sanitary design standards and integrates seamlessly with your existing equipment. Moreover, PFI provides comprehensive support, from initial design and engineering to installation, training, and ongoing maintenance, safeguarding your investment and maximizing the long-term value of your vibratory conveyor system.

ADDITIONAL COST CONSIDERATIONS 

Remember the costs beyond buying the conveyor. Installation, training, and ongoing maintenance can all add up over time.

Installation

Installation of vibratory conveyors is typically a separate service from the cost of the machine itself. Factors like the project complexity, location, whether structural changes are needed, and the total installation time will all impact the final installation cost.

Training

Vibratory conveyors are designed for easy operation. PFI offers basic training resources (e.g., manuals and videos) at no extra cost. We train staff at installation and can host additional training for a fee. 

Maintenance

Vibratory conveyors are known for their low maintenance requirements. Their minimal moving parts translate into lower operational costs over their lifetime. However, routine upkeep is crucial in maximizing their lifespan and performance. This typically involves replacing vibratory springs once or twice a year and properly tuning the motors. 

The relatively low cost of these replacement parts contributes to the overall cost-effectiveness of vibratory conveyors. 

Operational Expenses (Energy Consumption)

Properly tuned mechanical vibratory conveyors are remarkably energy-efficient. Due to their design, electromagnetic conveyors can offer even lower energy consumption. This energy efficiency can significantly reduce operating costs over time.

PRICE ESTIMATES

The price of a vibratory conveyor depends heavily on size and customization. For a more accurate idea, getting a quote directly from a manufacturer is best.

Base Models

The price of a base model vibratory conveyor varies depending on its model, size, and built-in features. For example, smaller conveyors can run anywhere from $25,000 to $100,000+.

Customized Models

Vibratory conveyors with extensive customizations or complex system requirements are harder to price without detailed specifications. The wide range of possible options, sizes, and features make fixed estimates challenging.

LIFETIME VALUE AND COST

Regular maintenance is crucial to get the most out of your vibratory conveyor. It extends the lifespan and optimizes performance. Keeping your conveyor in good working order can minimize downtime and increase productivity.

Due to their limited moving parts and longer lifespan, vibratory conveyors have a lower lifetime cost than belt conveyors. This advantage enables them to operate with reduced maintenance requirements and increased uptime. At PFI, we build our conveyors with high-quality materials to deliver reliable performance and durability.

A well-designed conveyor tailored to your specific needs can also reduce the total cost of ownership and maximize return on investment. Additionally, it offers impressive energy efficiency, which reduces operating expenses over time. A customized conveyor solution allows you to streamline your operations and stay ahead of the competition.

GET THE RIGHT VIBRATORY CONVEYOR SOLUTION WITH PFI 

The cost of a vibratory conveyor system depends on various factors. That’s why partnering with PFI is crucial. Our team of experts will guide you in selecting the ideal vibratory conveyor for your needs. We’ll ensure you get the best value for your investment.

Click below to learn more about our vibratory conveyors and the value they’ll add to your production line.

View Our Vibratory Conveyors

Walnuts going into a PFI bucket elevator

Maximize Your Pfi Bucket Elevator Performance With the Right Bucket Options

Written by Howard on .

Keeping your food production line running smoothly requires regular maintenance, and that includes your bucket elevators. Over time, buckets wear and tear, needing replacements to maintain optimal performance. But replacement buckets aren’t just about fixing wear and tear. Your needs can evolve too.

Read on to learn about the many bucket options available for your PFI Bucket Elevator.

PFI: YOUR BUCKET EXPERTS

Having built our reputation as Meyer Industries, we now offer seamless compatibility across the entire PFI product range, including legacy Meyer machines. 

UNDERSTANDING YOUR BUCKET OPTIONS 

We offer a wide range of buckets to suit diverse applications and food processing requirements:

Materials:

  • Polycarbonate (standard)
  • Polyethylene
  • Stainless steel

Features:

  • Ribbed
  • Colored
  • Metal-detectable
  • Split

PFI has a wide range of bucket sizes to match your specific needs. Bucket widths include 6, 9, 12, 15, 18, 24, 30, 36, and 48 inches. Depths vary based on the model and width, ranging from 2 ⅝” to 6”.

It’s important to note that PFI buckets are specially engineered to work exclusively with PFI and Meyer bucket elevators. This guarantees seamless fit and optimal performance.

Here’s a side-by-side comparison:

Bucket Type Key Features Ideal Applications
Polycarbonate Impact-resistant, standard material Most food processing applications
Polyethylene Low heat deflection, chemical resistance, quieter operation Applications with heat sensitivity and sound reduction needs
Stainless Steel High-temperature resistance High-heat settings, product/customer requirements
Ribbed Enhanced product release Sticky materials (gummies, etc.)
Colored Color differentiation Separating products, aligning with customer branding
Metal-Detectable Ensures safety compliance Food processing with metal detection policies
Split Keeps products separate Conveying multiple products at once

HOW WE DETERMINE THE PERFECT BUCKET FOR YOU

Pasta in a PFI bucket elevator

To ensure optimal performance, PFI considers several factors when recommending the right bucket type for your needs:

  • Throughput Requirements: Your bucket elevator’s dimensions and speed determine its potential throughput.
  • Product Type: The product characteristics influence the ideal bucket material. Our polycarbonate buckets excel in most cases and offer a versatile solution. For irregularly shaped products, we may recommend oversized buckets with greater depth. This ensures secure transport and reduces potential spillage
  • Bucket Fill: A general rule of thumb is not to fill buckets past ⅔ capacity, although specific products may work better with oversized buckets to accommodate their shape.

HOW MUCH DO BUCKETS COST? 

Bucket type and size are the two biggest factors influencing the overall cost. Understanding these differences helps you make a more informed decision:

Material: Stainless steel buckets carry the highest price tag due to their custom fabrication. Polycarbonate, our standard material, is the most affordable, thanks to bulk molding. Specialty buckets, like ribbed or split versions, may also have a premium due to lower production volume.

Size: Bucket size has a relatively minimal impact on individual bucket prices. However, larger bucket elevators require more buckets, affecting the total cost. For example, the price to purchase replacement buckets for a 20-foot bucket elevator ranges approximately 10-15% depending on the width of the buckets.

For detailed quotes tailored to your existing elevator or a new need, don’t hesitate to contact our team.

PFI BUCKETS DELIVER OPTIMIZED PERFORMANCE

Unlock your bucket elevator’s full potential with the right PFI buckets. As the OEM for PFI and Meyer bucket elevators, our replacement buckets are guaranteed for a perfect fit, maximizing performance for both your legacy Meyer machines and your new PFI equipment.

Click below to explore our innovative Bucket Elevators and learn how they optimize efficiency and productivity.

See Our Bucket Elevators

A PFI sanitary conveying system in operation

7 Ways Conveyors Can Boost Food Manufacturing Productivity

Written by Howard on .

In the fast-paced world of food manufacturing, efficiency is king. While conveyor applications in food manufacturing have traditionally focused on simply moving products between stations, their role can be much more impactful. 

By leveraging innovative food manufacturing conveyors, manufacturers can unlock a new level of productivity and profitability. Let’s explore ways you might already be using conveyors – and some ways their unique functionality could offer added benefits for your processes.

1. CONVEYING FROM A TO Z

Conveying is the backbone of food manufacturing, integrating production processes throughout the line. Several conveyance solutions—from belt conveyors to vibratory and horizontal motion conveyors and more—transport products from one end of production to the other. 

While general conveying can be deemed an afterthought, the right technology and durable equipment are vital to keeping production running, product integrity, and food safety. There are many considerations when selecting the right sanitary conveyor – from application needs to sanitation levels. 

When food processors use conveyors to perform value-added applications like laning, grading and sizing, and topping application, they can achieve even more with the same footprint and budget.

2. Bulk Handling for Big Production

Bulk handling solutions introduce and manage large volumes of ingredients or loose products within the food processing line. Equipment systems consisting of dumpers, augers, storeveyors, and more hold and process products to keep production running efficiently. 

Beyond moving a large quantity of product, bulk-handling conveyors can optimize how those materials are introduced to your process. Controlled release from storage systems can smooth out product flow, preventing surges that might overwhelm downstream equipment. They can also feed products into multiple processing streams to enhance capacity and throughput.

3. Elevating Efficiency 

Elevating conveyors maximize floor space, allow you to increase production on a platform or mezzanine, and seamlessly integrate equipment and processes at different heights. By conveying vertically with belt incline conveyors, positive lift conveyors, screw augers, and bucket elevators you increase capacity and efficiency in a tight footprint. 

Don’t just go up. Integrate inspection, X-ray, and other applications to add additional value.

4. Enhancing Mix Integrity

Mixing and blending solutions automatically maintain mix integrity for a wide range of foods like mixed nuts, snacks, trail mixes, and vegetables. Implementing Mix-Blend Systems that combine bulk handling hoppers and dumpers with vibratory feeders and collection conveyors provides precise recipes that improve yield, profitability, and product quality. These systems are configured to plant layouts and product mix needs.

Enhance performance, volume, and flow rate with automatic recipe-driven control systems that adjust on the fly – keeping your recipe consistent throughout production runs. 

5. Merging and Sorting Product Flow 

Merging and sorting conveyors optimize production and efficiency by seamlessly combining or separating multiple product flow lines between downstream and upstream processes. Reversing horizontal motion conveyors or a selection of belt conveyors keeps production running while maximizing throughput to multiple processes. 

These merging and sorting solutions don’t just move products. You can also rely on these conveyors to accurately maintain alignment, orientation, and positioning for the most efficient handling and processing. 

PFI PURmotion conveyor moves product with control over feed rate and reversibility.

6. Accumulating Performance

Accumulating conveyors play a key role in modern food processing lines. By temporarily storing and gathering products, they prevent disruptions, ensure a consistent product flow, and bolster production smoothness. 

Storeveyors, distribution systems, and reversing horizontal motion conveyors’ ability to buffer against surges or starvation keep your line operational and avoid downtime.

High-volume product accumulation is only valuable if it’s on your terms and appropriately handles the product. Look for configurable solutions with sanitary stainless steel design, sensors, automatic controls, and first-in-first-out discharge options. 

7. Precise Product Positioning 

Positioning conveyors like retractors and spreaders ensure products are accurately oriented and placed for subsequent processing steps. These conveyors orient, spread, index, or deposit products into rows and stacks, significantly increasing efficiency by manipulating products in-process and seamlessly connecting processing steps. 

Integrating positioning belt conveyors maximizes production space and capex budget. Their versatility makes them applicable to a wide range of food manufacturing lines.

DISCOVER HOW PFI INCREASES FOOD PROCESSING PRODUCTIVITY 

Conveyors significantly enhance application productivity and efficiency. Food manufacturers can streamline operations, reduce labor costs, and increase output by utilizing conveyors for more than simple transport. 

At PFI, we tailor our innovative conveyor solutions to meet our customers’ food processing and manufacturing needs. Click below to learn more about our range of food-conveying equipment that will improve your plant’s efficiency, productivity, and safety.

See Our Food Conveying Equipment

PFI PURmotion conveyor moves product with control over feed rate and reversibility.

6 Ways to Keep Your Sanitary Food Conveyor in Good Shape

Written by Howard on .

Unexpected conveyor breakdowns can wreak havoc in food production facilities. Halted production lines, food safety risks, and increased costs are just some disruptions that can occur. 

However, these issues pale compared to the expense and downtime of replacing an improperly maintained conveyor system.

The good news is that there are several steps that food processors can take to minimize these risks and keep their production lines running smoothly. 

  1. Conducting Thorough and Regular Inspections
  2. Lubricating and Replacing Worn-Out Parts
  3. Emphasize Staff Training and Continuous Improvement
  4. Tailoring Maintenance for Different Types of Conveyors
  5. Documentation and Optimization
  6. Getting Outside Support for Major Repairs and Overhauls

Read on to discover how to maintain your food conveyor, avoid expensive disruptions, and maintain an efficient operation.

UNDERSTANDING THE LIFESPAN OF FOOD CONVEYORS

The lifespan of various types of food conveyors can differ significantly:

These estimations are based on general trends and can vary according to how well the conveyors are maintained, the frequency and type of use, and exposed environmental conditions.

Proper maintenance can significantly extend a conveyor’s lifespan. Regular inspections, timely repairs, and part replacements can add years to a conveyor’s service life, preventing the premature need for costly replacements. This proactive approach to maintenance ensures continuous operation and contributes to the conveyor system’s overall longevity.

CONVEYOR CLEANING SOLUTIONS 

Maintaining a clean conveyor system is crucial for ensuring overall efficiency and longevity. Regular cleaning helps prevent the buildup of debris and contaminants, which can lead to equipment failure, increased wear, and potential contamination of food products.

Different conveyors require specific cleaning methods to ensure optimal performance and sanitation. Common cleaning solutions include:

  • Belt Conveyor Cleaning: Often involves using scrapers, brushes, and washdown systems to remove debris and clean the belt surface.
  • Vibratory Conveyor Cleaning: Air knives, vacuums, and washdown systems may be used to clean the pan and remove debris.
  • Horizontal Motion Conveyor Cleaning: These solutions usually utilize washdown systems, brushes, and air knives to clean the conveyor and remove debris.
  • Bucket Elevator Cleaning: This may involve using brushes, air knives, and washdown systems to clean the buckets and elevator components.
  • Dumper Cleaning: Typically use washdown systems, brushes, and air knives to clean the dumper components and maintain a sanitary environment.

It is crucial to confirm that cleaning and sanitation protocols deliver the expected efficacy through microbial testing and visual inspections. Validate that all surfaces meet sanitary guidelines and adjust methods as needed based on actionable test results.

After processing frozen french fries, a vacuum or air knife might be needed to clean this vibratory conveyor.

With that in mind, the appropriate cleaning solution for your conveyor will depend on the conveyor type, the materials conveyed, and the specific application in the food processing environment.  

KEY MAINTENANCE STRATEGIES FOR FOOD CONVEYORS

Six essential maintenance actions can help food processors extend the lifespan of their food conveyors and prevent unscheduled breakdowns. 

1. Conducting Thorough and Regular Inspections

Refer to the manufacturer’s equipment manuals for maintenance checklists and recommended inspection frequencies as an ideal starting point. These specifications outline optimal operating conditions, preventative upkeep cadences, safety information, and performance logging details unique to each system.

Preventative conveyor maintenance should be systematic and thorough. Technicians can use checklists tailored to different types of conveyors, detailing specific inspection points for each model. This process includes: 

  • Checking for damage, wear and tear
  • Ensuring alignment, and 
  • Monitoring the operational functionality of belts, pulleys, motors, and other critical components
  • Confirming safety component operation.

Food manufacturers can handle these regular checks internally with proper training. However, for more rigorous quarterly assessments, bringing in a specialist to help is advised. Comprehensive evaluations keep all mechanical and electrical aspects running safely and efficiently.

2. Lubricating and Replacing Worn-Out Parts

Lubricate moving components basic every few months. More involved biannual deep lubrication procedures may require outside specialists. Timely replacement of worn parts like belts, springs, and bushings also prevents breakdowns. 

Maintain an inventory of commonly replaced wear parts like belts, springs, and bushings to avoid production delays when replacements are needed. Having these essential spares on hand allows technicians to swap components rapidly and prevents the downtime of emergency parts procurement.

While staffers may be able to change out basic parts internally with some guidance, planning for specialty part fabrication or sourcing requires conveyor technician expertise. The specialized skills of expert technicians are best suited to source and design custom or intricate replacement components.

Proper lubrication and part replacement reduce friction and wear. This extends the lifespan of conveyors, cutting replacement costs significantly. It also leads to smoother operation and less unscheduled downtime. 

3. Emphasize Staff Training and Continuous Improvement

Regular staff training is vital for maintaining conveyor systems. Training sessions should cover basic maintenance and safety protocols and focus on continuous improvement strategies. 

By collaborating with industry specialists, employees receive comprehensive training beyond the basics. These sessions share best practices for equipment: 

  • Installations
  • Calibrations
  • Testing
  • Providing in-depth knowledge and hands-on experience with new and existing equipment.

The goal is to boost performance and prevent accidents through improved maintenance and safety habits. Ongoing education and collaboration with experts cultivate a culture focused on preventative care instead of reactive repairs. 

This proactive approach maximizes equipment lifespan and productivity and empowers employees to uphold rigorous safety standards to achieve operational excellence.

4. Tailoring Maintenance for Different Types of Conveyors

Each type of food conveyor system has unique maintenance needs. A one-size-fits-all approach to conveyor maintenance will not work. The required tasks vary widely depending on a system’s design, age, and usage.

A bucket conveyor is used to convey pet food during processing.

Belt Conveyors: Regular checks for belt alignment and wear are crucial. Monitor belt speed and vibration and ensure pulleys and bearings are in good condition.

Vibratory Conveyors: Focus on the regular tensioning of springs and tuning of motors. Also, inspect the construction of the pan for wear or damage.

Horizontal Motion Conveyors: Regularly inspect for bushing wear and assess the condition of the pan construction.

Bucket Elevators: Check the buckets for wear or damage, ensure the integrity of chains and sprockets, and confirm that drives and motors function correctly.

Dumpers: Maintain the stainless steel hydraulic cylinders and panel walls regularly.

Understanding and applying these specific food conveyor maintenance tasks are key to the effective upkeep of each type of conveyor system.

5. Documentation and Optimization

While food manufacturers can handle basic performance tracking and maintenance logs in-house, consider partnering with specialists for more complex needs. Comprehensive documentation ensures all conveyor data is readily available for failure and cost analysis.

Documentation

Regular visual inspections, lubrication, wear parts replacement, and sanitation should be logged and stored. These maintenance logs can diagnose decreased uptime reasons or determine when it’s time for a repair, modification, or replacement.

Optimization

While routine maintenance is manageable alone, consultants help manufacturers optimize production system-wide, utilizing documented data. Documentation gives internal teams and specialists the visibility of data to maximize performance. Their expertise can spot underlying issues and identify improvement opportunities.

Veteran technician guidance helps uncover optimization opportunities and innovations to minimize persistent issues. This breadth of experience provides an invaluable external perspective that spots potential blindspots to efficiency.

6. Getting Outside Support for Major Repairs and Overhauls

Food manufacturers can often do basic tasks like inspections and part replacements themselves. But it’s better to hire conveyor specialists for more extensive repairs or complete equipment checks.

Regular food conveyor maintenance keeps a PurMotion conveyor in excellent condition.

Major overhauls demand specialized expertise—thoroughly inspecting subsystems, rebuilding components, and validating overall integrity require skills that are challenging to match internally. Attempting substantial overhauls without appropriate capabilities risks improper assembly, calibration issues, or safety violations.

It’s wise to rely on expert outside assistance for:

  • Full motor/drive-train rebuilds
  • Complete belt/chain replacements
  • Electrical or sensor diagnostic checks
  • Life cycle cost modeling
  • Comprehensive health assessments

SELECTING THE RIGHT CONVEYOR MAINTENANCE PARTNER

Selecting the right conveyor maintenance partner is key for long-term success in food processing. As a leading manufacturer, PFI understands the needs of both conveyor equipment and facilities. Our guidance covers best maintenance practices, upgrades, and operator training.

We build reliable, efficient systems designed for compliance and easy upkeep. This sustains smooth operations over time. Additionally, we offer maintenance packages to optimize any equipment, even other brands. With deep industry expertise, PFI goes beyond just selling conveyors—our goal is to ensure maximum production uptime and throughput for food processors.

Our conveyors stand out in the industry for their durability and efficiency. On average, PFI conveyors have a lifespan of 10-15 years longer than most competitors. This is due to our commitment to using high-quality parts and materials and incorporating maintenance and sanitation-friendly design features.  

CHOOSE PFI FOR RELIABLE AND EFFICIENT CONVEYOR SOLUTIONS

Regular maintenance ensures improved efficiency, sanitation, and uptime. PFI sanitary conveyors help food processors maximize performance, reliability, and long-term savings. We invite you to explore our page below to learn more about our innovative food conveyor solutions.

See Our Food Conveying Equipment

Trends in pet food processing focus on higher-quality products.

Pet Food Processing Challenges

Written by Kimberly on .

Pet food manufacturers face many challenges when maximizing efficiencies, increasing yields, and decreasing waste. Conveying through the entire plant without causing contamination issues adds further complexity.

Integrating innovative food processing conveyors tailored to pet food manufacturing can help optimize operations. Many different types of conveyor solutions can improve line efficiency, quality control, and safety.

Read on to learn more about PFI’s sanitary pet food conveying systems and how they help processors solve these issues.

PET FOOD PROCESSING TRENDS TOWARD SANITARY DESIGN 

The pet food industry has significantly shifted towards incorporating raw, fresh, and frozen options in response to consumer demand for natural, high-quality pet diets. This evolution in food preferences emphasizes unprocessed and nutrient-rich choices that mirror natural dietary habits.

This movement towards raw and fresh ingredients indicates a paradigm shift from traditional pet food processing methods. The production process for minimally processed and fresh pet foods mirrors human food production. This includes maintaining proper temperatures for frozen ingredients and ensuring the cleanliness of raw ingredients. 

It’s imperative to employ sanitary manufacturing methods to make equipment accessible and cleanable. This helps ensure pet food safety while reducing downtime and extending shelf life.

Manufacturers can adapt to these trends by diversifying their product offerings and investing in versatile conveying equipment. This adaptability is crucial in a market that increasingly values a wide range of high-quality pet food options.

CHANGES IN PET FOOD PROCESSING OVER THE PAST 5-10 YEARS 

Pet food processing has advanced with the integration of meat grinders, chillers, and specialized packaging machinery. These new tools are essential for maintaining the freshness and nutritional value of pet food. 

Additionally, there has been a major shift in sanitation standards, with facilities now designed for easy cleaning and minimal contamination risk. These improvements are vital for ensuring the safety and longevity of pet food products, particularly those that are minimally processed or contain fresh ingredients.

A sanitary belt conveyor is used for higher quality control in pet food processing.

Several factors led to these changes in pet food processing: 

IMPACT OF THE PANDEMIC ON THE PET FOOD INDUSTRY 

  • As pet owners elevated food quality expectations, manufacturers faced the challenge of scaling up production and meeting increased demand for higher-quality products.
  • Investments in more efficient, higher-capacity production lines and the introduction of premium, health-oriented pet food options followed this shift.

MERGERS AND ACQUISITIONS (M&A) ACTIVITY IN THE PET FOOD INDUSTRY 

  • As pet food grew into a substantial market segment within the food industry, large food processors entered the field, bringing additional investment and expertise. They developed sophisticated, diverse product lines. 
  • These changes to pet food required advanced manufacturing techniques and higher quality control standards. 

ADAPTING TO MARKET DEMANDS: VERSATILITY AND EFFICIENCY IN CONVEYING EQUIPMENT

A bucket conveyor is used to convey pet food during processing.

Sanitary conveying equipment emerges as an effective solution to address these challenges. It enhances production efficiency and reduces labor costs. PFI offers a range of conveyors suitable for these needs:

  • Belt Conveyors: These conveyors are ideal for handling high and low temperatures. They facilitate product temperature management and direct-to-packaging conveyance.
  • Horizontal Motion Conveyors: Effectively handle kibble, biscuits, and wet food while minimizing the risk of contamination. Their gentle operation also preserves the integrity and quality of the food. They are also useful in mixing and blending.
  • Bucket Elevators & Incline Conveyors: Excellent for elevating products to mezzanines or tall equipment. This helps to optimize the plant footprint. 
  • Vibratory Conveyors & Feeders: Suitable for sanitary design needs, they offer gentle handling of pet food products.
  • Dumpers: Ideal for bulk handling, allowing for storage or accumulation during the process.

Each conveyor type addresses specific challenges in pet food manufacturing, from handling diverse product types to meeting high sanitation standards. 

VALUE-ADDED CONVEYING 

PFI conveyors do more than just transport products from one point to another. They also offer value-added features. For example, our conveyors can control the cooling or warming of products. This aids in the preservation and preparation of pet food.

We can configure our conveyors for sorting and quality control processes to enhance the production line’s overall efficiency. These capabilities highlight the multi-functional nature of our conveying solutions and contribute to process optimization and cost-effectiveness.

MAXIMIZING PLANT FOOTPRINT WITH CONVEYORS

During pet food processing, the product passes through a vibratory feeder.

PFI’s conveyors actively optimize the plant’s available space, improving the production setup’s overall efficiency. Building up strategies, such as elevating products to mezzanines or tall equipment like scales and baggers, are effectively supported by machines like bucket elevators, incline belt conveyors, and vertical lift conveyors. 

These solutions are crucial for optimizing space in manufacturing facilities. Additionally, conveyors adept at navigating facility constraints play a key role in space optimization, allowing for ambient temperature adjustment post-cooking or frying.

PFI: YOUR PARTNER IN PET FOOD PROCESSING 

PFI is a leader in sanitary conveyor solutions, backed by years of experience in the pet food industry. Our range of conveyors and expertise positions us as a valuable partner for manufacturers seeking to overcome current challenges and embrace future opportunities. 

By integrating our equipment, manufacturers can expect improved efficiency, higher product quality, and enhanced sanitation standards. 

Visit our pet food solutions page below to explore our wide range of solutions.

See Our Pet Food Solutions

A vibratory conveyor evenly distributes frozen chicken nuggets across the processing line.

How to Maximize Your Food Plant Footprint with Conveyors

Written by Kimberly on .

Many food manufacturers struggle with limited facility space that restricts their ability to expand operations and increase production. Cramped layouts not only impact efficiency but also pose safety hazards. Managing the available footprint is critical for increasing productivity and profitability.

Food conveyors provide an effective strategy to maximize production space by better utilizing not just the floor area but the entire volume of the plant. Conveyors can transform facility layouts and open up new configuration possibilities that facilitate improved throughput and efficiency. Using one piece of equipment for multiple purposes can also reduce the overall footprint of a food plant.  

Read on to learn more about optimizing your facility with innovative conveyor solutions.

BUILDING UP WITH CONVEYORS

Manufacturers facing spatial limitations can unlock the potential of their existing footprint by leveraging vertical space. This strategic solution enhances production capacity without expanding the facility’s ground area. PFI’s vertical conveying systems are key to overcoming these challenges.

Advanced Vertical Conveying Systems

PFI offers advanced conveying systems such as bucket elevators, incline belt conveyors, and vertical lift conveyors. They facilitate upward expansion and enable manufacturers to elevate products to different processing levels, including mezzanines. This increase in the usable volume of the plant maximizes the production area and streamlines processes. 

The Bucket Elevator easily lifts various bulk materials in a small footprint. It provides a continuous flow and minimizes transfer points. The Eleveyor incline belt conveyor is ideal for delicate products, ensuring gentle handling to maintain quality during elevation. The PURlift vertical lift conveyor offers a sturdy design for more demanding applications, ensuring secure elevation. This is crucial for maintaining the integrity of the products.

These elevation systems integrate seamlessly into existing processes. Adopting a vertical conveying solution allows food manufacturers to effectively address space constraints, scale production, and bolster profitability.

Ceiling-Mounted Conveyors

Ceiling-mounted conveyors are instrumental in maximizing space within manufacturing facilities. This design involves suspending a transport system from the ceiling. These innovative systems utilize often-underused overhead space to elevate materials and products above the production floor. 

This approach frees up valuable floor space for more operational activities and contributes to a less cluttered and safer work environment. PFI can adapt these systems to various load types and tailor them to meet the specific requirements of any manufacturing operation.

Construction Considerations for Elevation

Elevating products may require extra structures like mezzanines, platforms, access stairs, and catwalks. PFI manufactures these support structures and components like small elevators ideal for transporting totes and components. This helps maximize the use of vertical space while integrating smoothly into your facility’s elevation system.

GOING AROUND: OTHER WAYS TO INCREASE SPACE 

Conveyors play a vital role in food processing, not only for transportation but also for product quality enhancement post-cooking. The Curveyor, a unique curved belt conveyor from PFI, exemplifies this multi-functional approach. It expertly navigates obstacles like pillars, walls, and doorways. This enables manufacturers to use previously inaccessible areas, maximizing the facility footprint. 

The Curveyor maximizes a food plant's footprint by facilitating product flow in the most challenging layouts.

The Curveyor facilitates fluid product flow even in challenging layouts, enhancing production without expanding the facility’s footprint.  It minimizes the need for extensive modifications or additional square footage, efficiently using every available space in a facility.

VALUE-ADDED CONVEYING

Conveyors in food processing serve a variety of functions beyond product transportation. They streamline operations, consolidate equipment needs, and minimize the required floor space, leading to cost savings. PFI can equip them to perform many actions directly on the conveyor line, such as flipping, sorting, aligning, spacing, sizing, and even product treatment tasks, which traditionally require separate machinery. 

This approach, known as value-added conveyance, turns our equipment into multi-purpose tools. This multi-functional capability ensures you get more from your equipment, enhancing efficiency and reducing the need for additional machinery. Consolidating multiple processes into a single piece of equipment reduces the necessary floor space, optimizing the available area. 

Sizing, Grading, and Screening

Vibratory conveyors are the most versatile conveyors to add value throughout your processing line. One of the most prominent applications is separating products of various sizes. Whether separating different-sized products into multiple streams or screening out small pieces or fines, our VFII electro-mag vibratory conveyor ensures efficiency and optimal product flow without manual intervention or additional footprint. 

Aligning and Positioning

Ensuring products are in the right position for the next step in the process is vital for consistent flow and high production. Aligning and positioning solutions include conveyors that orient, spread, index, or deposit products while in motion.

The Retractor is a versatile conveyor that transfers, positions, arranges, deposits, loads, or rejects products 90 degrees to the next process without breakage or loss. This allows flexible line configurations and optimal space usage.

The Spreader preserves orientation while transferring products between narrower and wider sections of your processing line.

Merging and Sorting

Enabling multiple product flows that combine or separate between upstream and downstream processes optimizes production volume and efficiency, not to mention footprint. Our PURmotion horizontal motion conveyor features immediate reversing operation to feed two lines simultaneously and accumulate short-term, in addition to its superior gentle product handling and sanitary design.

Product Processing and Finishing

You might not first consider a conveyor to process or finish your food products, but these solutions can often handle these applications and eliminate the need for additional processing equipment. For example, using straight and curved belt conveyors to bring products to ambient temperature while transferring them to packaging. Or using vibratory conveyors to apply seasoning or sprinkles or enrobe a chocolate coating. 

This multifunctional use of conveyors adds significant value. It saves time, reduces labor costs, addresses workforce shortages, and improves food safety and processing precision. Incorporating these versatile conveyors into your food processing line can lead to a more streamlined, efficient, and cost-effective operation.

OPTIMIZING PRODUCTION WITH OEM INTEGRATION 

Efficient production flow is key to maximizing food plant footprint with conveyors. Expert OEM integration allows for the highest production efficiency. Investing in flexible, high-capacity equipment prepares your facility for future growth and diverse product mixes.

Our approach encourages processors to think creatively about their existing space. Rather than designing away from obstacles or expanding the facility’s footprint, our conveyors can navigate around them, using every available inch. This philosophy helps avoid unnecessary redesigns and construction, saving time and resources while enhancing production efficiency.

ENSURING SAFETY AND DURABILITY

PFI conveyor lines prioritize worker safety and the highest food hygiene standards.

While maximizing your facility’s footprint, it’s vital to recognize the importance of worker and food safety. We design our equipment to prioritize safety, featuring safeguards to protect employees and maintain the highest food hygiene standards. 

PFI’s equipment configurations prioritize safety by addressing crucial aspects such as head clearance under elevated structures and around other machines. Robust structural support prevents any risk of items falling from ceiling-mounted equipment, while a design with minimal moving parts ensures a secure operational environment. Additionally, features like non-slip surfaces on platforms and well-designed guarding for mezzanines contribute to an overall commitment to creating processor systems that prioritize the well-being of operators and minimize potential hazards.

From start to finish, we ensure that increasing your production capacity never comes at the cost of safety.

At PFI Conveyors, we prioritize sanitation and ease of maintenance in our equipment design. Our conveyors feature accessible components to simplify cleaning and upkeep. This reduces downtime while upholding rigorous food safety standards. We construct robust, durable systems that guarantee both peak performance and accessibility. 

TRANSFORM YOUR FACILITY WITH INNOVATIVE CONVEYOR SOLUTIONS 

The PFI team are experts in food plant optimization. For over 60 years, we have been helping customers maximize their production capacity through custom conveyor solutions that efficiently utilize all available space. 

Click below to learn more about our innovative conveyor solutions that will save space, improve efficiency, and increase your bottom line.

Contact an Expert

Sanitary conveying, delivered.™

Contact us

300 Kofab Drive
Algona, IA 50511


515.295.7265


sales@pficonveyors.com

Quicklinks

Contact Us

© 2024 PFI. ALL RIGHTS RESERVED. | Privacy Policy | Terms and Conditions