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Customer Background: A leading convenience food processing equipment manufacturer in India faced a recurring issue with their fryer setup, which was causing significant damage to their Flat-Flex® belt. The damage not only disrupted their production processes but also resulted in costly downtime and operational inefficiencies.

The Challenge: The customer’s fryer setup was facing mechanical issues that were leading to wear and tear on the Flat-Flex® belt. This was a critical issue, as it affected the smooth flow of their production line and impacted their overall throughput. The customer noticed these problems over time but it had become increasingly difficult to pinpoint the exact causes.

In order to better understand the root of the problem, they reached out to Swakster, our trusted distributor in India, to assist them in finding a solution.

The Approach: Our team, in collaboration with Swakster, worked closely with the customer to analyse the problem. The customer provided detailed photos showing the damage to the Flat-Flex® belt. From these images, we were able to identify two primary factors contributing to the belt wear:

  • Misalignment of the machine setup: Certain components of the machine were not properly aligned, causing the belt to rub against rough edges.
  • Excessive tension on the belt: The belt was being stretched too tightly, which created additional strain and led to accelerated wear.
  • Incorrect drive set up: The sprockets were being used in adjacent spaces which was causing the strand to twist and flex.  If left this will eventually lead to fatigue failure.  

The Solution: With the issues clearly identified, our team recommended the following adjustments:

  • Realigning the machine components to ensure smooth operation and prevent unnecessary friction.
  • Adjusting the belt tension to the optimal level, ensuring it was not too tight and therefore reducing strain on the system.
  • Sprocket arrangement setup guidance to ensure longevity of the belt.

These adjustments were implemented by the customer with assistance from Swakster. We also provided guidance on regular maintenance checks to ensure the longevity of the Flat-Flex® belt and the smooth operation of the entire system.

The Results: After implementing the solution, the customer reported significant improvements in their operations:

  • Reduced damage to the Flat-Flex® belt: The new setup minimised wear and tear, extending the life of the belt.
  • Improved production efficiency: With the machine running smoothly, the customer was able to reduce downtime, leading to higher throughput and less disruption in their operations.
  • Cost savings: The customer saw a reduction in maintenance costs and minimised the need for frequent belt replacements.

Customer Testimonial: “We are extremely grateful to Swakster and Wire Belt Company for helping us solve our machine setup issues. The adjustments they suggested have greatly improved our production line and we’ve seen a noticeable reduction in belt damage. We are now able to run our operations more efficiently and cost effectively. Thank you for your strong expert support!”

If you need assistance with your conveyor belt drive set up please don’t hesitate to contact us today! Our team at Wire Belt Company Ltd are ready to assist you.

Phone: +44 (0) 1795 421771

Email: sales@wirebelt.co.uk