High-Tech Dairy Faces Crate Conveyor System Inefficiencies.
Our client*, a major dairy manufacturer in Saudi Arabia with a high-tech factory in the Gulf, distributes fresh products in reusable plastic crates. These crates are collected back from the market, cleaned, and fed to the packer. However, their system presented significant challenges in crate transport and handling on conveyors.
Crates Conveyors
Due to a confidentiality agreement, we are keeping our client name anonymous
Friction and Crates Damage Leading to Production Downtime and Increased Maintenance Costs.
As crates traveled on long conveyor belts from cleaning to production areas, intense friction between the crates and the chains caused considerable damage and wear on both surfaces, which led to:
🔸damaged crates 🔸frequent chain and conveyor breakdowns 🔸production disruption and shutdowns 🔸Increased maintenance.
Both wet and dry lubrication failed to solve the issue. A significant amount of water from crate washers diluted wet lubricants, while dust mixed with dry lubricants created abrasive conditions. Excessive oil was required because the chain has a narrow contact area, and the crate, despite its large surface, sits on narrow strips. Facing mounting disruptions and waste, the dairy producer turned to Praucs for a solution.
Implementing a Customized Precision Lubrication Strategy with Advanced Lubricant and Equipment.
We first analyzed crate friction levels and conveyor motor energy consumption. We know that reducing friction between crate and chain is key to stopping abrasion, and adjusting friction between chain and wear strip will stop chain elongation and sudden breakage. Hence, we implemented a customized lubrication strategy:
Achieving Operational Excellence with Over 50% Reduction in Crate Damage and 3X Chain Lifespan.
By addressing the root cause of the problem, we helped our client achieve considerable cost savings and operational efficiency. The impact was immediate and measurable.
Since implementation in 2017, the client’s production line has operated smoothly, achieving ROI in the first year.
Our solution provides exceptional protection and sliding with micro quantities, ideal for dusty areas and narrow contact surfaces. It effectively coats small or porous surfaces. The precise, maintenance-free lubrication equipment requires no frequent calibration; once installed, it works seamlessly Â
“We’re amazed at the transformation. Praucs’ solution for the crates issue was truly a game-changer.” (The Operations Manager.)
*Due to a confidentiality agreement, we are keeping our client name anonymous.
