Efficiency is the magic ingredient in food production. Large-scale food manufacturers operate round-the-clock to meet demand, so a seamless conveyor system is important for keeping operations running smoothly. Whether you’re palletising packaged biscuits, moving frozen foods into cold storage, or transporting pre-packed meat products, your conveyor system can significantly impact productivity. But how do you design a conveyor that can handle the relentless nature of 24/7 production? That’s where we come in.
MCL specialises in custom conveyor solutions that optimise palletising and storage processes, ensuring durability, efficiency, and compliance with food safety standards. We understand the unique demands of high-use conveyors in food production. Designing a conveyor system for non-stop operations isn’t just about moving products from point A to B – it’s about minimising downtime, enhancing automation, and providing long-term reliability.
In this article, we’ll explore the challenges of designing conveyor systems for continuous operations and the critical features that make them both robust and effective.
Running a food production line 24/7 presents unique challenges. Without the right conveyor design, you risk bottlenecks, excessive wear and tear, and disruptions that could bring operations to a standstill. Here are some of the key challenges:
Food production lines often process thousands of packaged goods per hour, so they need conveyor systems that can handle high volumes, providing for transportation, accumulation and sortation to maximise output. If the system isn’t designed to handle high throughput efficiently, bottlenecks can form and lead to costly delays. A well-planned conveyor layout helps products move seamlessly from production to palletising and storage without interruptions.
Continuous operations take a heavy toll on conveyor components. The constant movement and heavy loads can cause significant wear and tear, and even mechanical failures if the systems aren’t designed for longevity. High-quality materials and precision engineering are the best defence to prevent frequent breakdowns and maintenance disruptions.
Food products may move through various temperature zones—some need to be transported from ambient conditions, through to sub-zero environments for storage. Conveyor systems need to be designed with materials that can endure extreme temperatures without compromising on performance.
Maintaining a high level of hygiene is the golden rule of food production. Conveyor systems must comply with strict food safety standards and be easy to clean. This means using washdown-rated components that can withstand high-pressure cleaning while minimising the risk of bacterial contamination.
Automation is revolutionising the food production industry. Conveyors must integrate seamlessly with robotic palletisers, sorting machines, labelling systems, and warehouse management software to ensure a fully automated and efficient workflow in the long-term.
To overcome these challenges, a conveyor system must be built with durability, hygiene, and efficiency in mind. Here’s what sets our high-performance conveyors apart:
Conveyors for continuous operations need to be built with longevity in mind. Using stainless steel and corrosion-resistant components ensures the durability of your system. These materials can withstand everything from long-term use, heavy loads, rigorous cleaning processes, and temperature fluctuations.
A conveyor is only as good as its ability to integrate with modern automation systems. MCL provides conveyors that fit in seamlessly with robotic palletisers, automated storage and retrieval systems (ASRS), and warehouse management software, streamlining operations from packaging to shipping.
Continuous operations demand powerful and energy-efficient motors. High-performance drive systems reduce wear and tear while keeping your goods moving smoothly and consistently. Reliable motors also minimise any downtime, keeping production lines running without interruptions. At MCL, we utilise our cutting edge PulseRoller technology for increased control and system longevity, ease of maintenance (should it be needed) and decreased downtime.
Conveyors operating in extreme conditions—whether moving frozen foods to cold storage or handling products in high-heat environments—must be designed with temperature-resistant materials. MCL provides conveyor systems that maintain optimal performance in both ambient and sub-zero settings.
Food production facilities require conveyors that meet strict hygiene regulations. Washdown-rated conveyor systems (IP66) can be easily cleaned and sanitised, keeping you compliant with food safety laws while minimising contamination risks.
Efficient palletising and storage are vital to your operation. Here’s how conveyor solutions streamline these processes:
With decades of experience in designing conveyor solutions, MCL has partnered with some of New Zealand’s leading food manufacturers. From Fonterra to Bluebird Foods and Tip Top Ice Cream, the cream of the crop relies on MCL’s expertise.
Our customised conveyor designs are built to withstand the demands of high-speed and high throughput food production, ensuring a seamless integration with palletising and storage systems. Our solutions prioritise durability, automation, and food safety, helping food producers maintain continuous operations without disruptions.
A reliable conveyor system is the foundation of efficient palletising and storage in large-scale food production. Without robust, high-performance conveyors, you risk bottlenecks, downtime, and hygiene concerns, which can compromise food safety and your reputation.
At MCL, we understand the unique demands of 24/7 food production and offer customised conveyor solutions built to last. Whether you need a system for high-throughput palletising, cold storage integration, or automated sorting, we design conveyors that keep your operations running smoothly.
Ready to optimise your conveyor systems? Get in touch with our team today to discuss your unique needs, and discover how our tailored solutions can improve your efficiency.