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TABLE OF CONTENTSConveying Cleanliness 5

The right materials and design can make it possible for a conveying system, of any kind, to

achieve reliable sanitation.

Factors to Consider When Sourcing Pneumatic Conveying Systems

for Powders That Are Difficult to Move 13

Food Grade Conveyor Systems: What You Should Know Before You Buy 16

Evolution of Conveyors in Food Processing 19

AD INDEXTuthill • www.tuthill.com 2

Citgo • www.clarionlubricants.com 4

Cablevey • www.cablevey.com 6

Rexnord • www2.rexnord.com/foodconveying 8

Rice Lake • www.ricelake.com 10

QC Conveyors • www.qcconveyors.com 12

Vac-U-Max • www.vac-u-max.com 15

Dynamic Conveyor • www.dynamicconveyor.com 18

Multi-Conveyor LLC • www.multi-conveyor.com 21

eHANDBOOK: Conveying / Sorting / Powder Bulk Handling 3

www.FoodProcessing.com

When it comes to what you do, you’re the expert. And when it comes to supplying food-grade lubricants backed by service-oriented professionals, we’re the experts. We work with you to create an efficient lubrication program that helps protect your operation.

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A speck of food residue on a con-

veyor is a potential time bomb.

Any product accumulation, no

matter how small, that allows microorgan-

isms to fester on a conveyor can rapidly

taint an entire production shift. Now that

DNA mapping can quickly trace microbial

contamination back to its source, the lia-

bility of a recall or worse that can deal a

lasting hit to a processor’s reputation is

greater than ever. Recent changes in the

law put even more pressure on processors

to pay attention to sanitation.

“The FDA Food Safety Modernization Act

(FSMA) is transforming food companies

by shifting the focus from responding to

foodborne illness and foreign material con-

tamination to preventing it,” says Soren

Pedersen, food global team leader for belt

supplier Intralox (www.intralox.com).

That’s why cleanability is among the highest

priorities that food processors have for con-

veyors. They’re long, complex systems that

move lots of product as quickly as possible.

Contamination has the potential to get

out of control before anyone realizes that

something is wrong.

There are, of course, a wide variety of

conveyors, and a lot of different ways of

keeping them clean – and of designing

them to be kept clean. Design aspects for

cleanliness include the nature of welds and

fasteners, the ease with which sections can

be disassembled, the finish of the metal,

the materials used in the belt or chain, the

nature of the power transmission compo-

nents, and more.

STEELY RESOLVE Perhaps the most basic specification for

cleanability in a conveyor is the use of

stainless steel for most of its construction.

Most food-grade conveyors marketed

today – at least, those intended for direct

product contact – are stainless steel,

which resists both microbial growth and

corrosion better than coated mild steel.

“Sanitary conveyor systems are stain-

less steel constructed, premium welded

Conveying CleanlinessThe right materials and design can make it possible for a conveying system, of any kind, to achieve reliable sanitation.

By Pan Demetrakakes, Senior Editor

eHANDBOOK: Conveying / Sorting / Powder Bulk Handling 5

www.FoodProcessing.com

(641) 673-8451www.cablevey.com

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and built specifically as dictated by san-

itation or food safety requirements,”

says Cheryl Miller, marketing director for

Multi-Conveyor (www.multi-conveyor.

com). “Any food conveyor manufacturer

has to keenly understand the need for

effective, easy-to-clean, CIP/COP [clean-in-

place/clean-out-of-place] and washdown

equipment.”

Another aspect to pay attention to is the

steel’s finishing method. When it comes

to corrosion, which increases in risk with

harsher washdown chemicals, grade 316

stainless performs better than 304. Accord-

ing to Jim Ruff, vice president of process

systems and integrated solutions at Key

Technology (www.key.net), a rotary polish

finish will leave the surface with a smoother

surface and inhibit microbial attachment

better than the alternative 2B mill finish. At

a minimum, he says, stainless steel and a

rotary polish should be considered within a

conveyor’s product contact zones.

However, when it comes to sanitation, it’s not

enough for a conveyor merely to consist of

stainless steel, says Stacy Johnson, director of

marketing and strategic planning for Dorner

Manufacturing (www.dornerconveyors.com).

“Just because a conveyor is stainless steel

doesn’t necessarily mean it’s sanitary,”

Johnson says. “A basic stainless-steel con-

veyor can be washed throughout the day

as needed, depending on how it is built, but

it’s not necessarily sanitized. That’s because

sanitizing or cleaning a conveyor involves

an entirely different process than simply

washing it down, and much of achieving a

sanitized conveyor depends on the way it

was initially designed.”

ROUNDING OFF The design for a sanitary conveyor

should involve as few points as possible

for product residue to accumulate, with

welded, rounded frames and minimal

fasteners in the food zones. Examples

include Dorner’s AquaPruf and AquaGard

conveyor systems and the DynaClean

sanitary conveyor from Dynamic

Conveyor (www.dynamicconveyor.com).

The DynaClean features a motor and

controls that can be removed without

tools, a belt that can be removed with

one lacing rod and retaining walls that

also can be removed without tools.

The biggest hot spot for sanitation in a con-

veyor is the product-contact surface – the

belt, pan, or tube that actually carries the

product. This is where it’s most important

that finish and choice of material match the

application. That means not only conveying

the product efficiently, but being compatible

with whatever sanitation method is required.

Typical belt materials, according to Key

Technology’s Ruff, are fabric, modular

plastic and solid plastic. Fabric belts are

liable to fray, presenting a significant

www.FoodProcessing.com

eHANDBOOK: Conveying / Sorting / Powder Bulk Handling 7

Increased Uptime and Less Downtime Depends on the Right Conveyor Belt

Rexnord’s full suite of food safe metal

and plastic modular belts give you

an end-to-end solution for your food

processing line. Our belting designs

have features that enable efficient

sanitation, installation and maintenance,

reducing downtime and optimizing

your total cost of ownership.

Learn more at www2.Rexnord.com/FoodConveying

sanitation problem, unless the edges are

encapsulated. Modular plastic is popular

for products with high water activity, such

as meat and poultry, where moisture needs

to drain away. But optimal from a sanitary

standpoint, Ruff says, is a seamless positive

drive urethane belt, which both eliminates

crevices and is relatively easy to disengage

for cleaning.

Other types of conveyors don’t use belts at

all. For instance, Heat and Control (www.

heatandcontrol.com) uses a variety of fin-

ishes for its Fastback horizontal-motion

conveyors, which convey fragile product

by sliding back and forth. Options include

an electropolish finish for delicate wrapped

candy, a rigidized one for frozen products

and a Tivar lining for products whose high

sugar content is liable to build up in the

conveyor bed.

The means of powering the conveyor

are just as important, from the stand-

point of hygiene, as the product-contact

surfaces. The nature and location of the

motors and their connections to the belt

have to be configured correctly to maxi-

mize cleanability.

The basic options for power transmission

are: standalone motors located along (usu-

ally beneath) the belt and connected to

gearboxes; gearmotors, which combine

motors and gearboxes in one unit, usually

enclosed; and drum motors, which are more

powerful motors, located at the end of the

belt loop, that pull the entire belt length.

Each has practical advantages. Separate

motors and gearboxes are usually cheaper,

because they’re standardized across a vari-

ety of industrial uses. Gearmotors are often

easier to specify and install, while drum

motors tend to be more energy-efficient.

But when it comes to sanitation, gear-

motors and drum motors have a distinct

advantage: Being enclosed makes them

stand up to washdowns better.

“This conventional arrangement of driv-

ing conveyor belts in the industry creates

numerous gaps and crevices for food

byproduct to accumulate, making it difficult

to clean and adding expense to the sani-

tation cycle,” says Rick Zander, business

development manager for VDG (www.van-

dergraaf.com). “These arrangements are

“Just because a conveyor is stainless steel doesn’t necessarily mean it’s sanitary”

www.FoodProcessing.com

eHANDBOOK: Conveying / Sorting / Powder Bulk Handling 9

MORE THAN A CHECKWEIGHERCheck Weight for Quality and Control

800-472-6703www.ricelake.com/motoweigh

Rice Lake Weighing Systems’ MotoWeigh® In-Motion Checkweigher and Conveyor System combines automation with powerful weighing features to provide users complete control over their conveying processes. Designed with food-grade stainless steel and remote access capability, the MotoWeigh gives food processors an edge over the competition.

Industrial-strength equipment for the most demanding jobs.

Checkweighers | Metal Detection | Bench Scales | Floor Scales | Balances | Process Controllers

susceptible to foreign material contamina-

tion due to the wear of the plastics that can

end up in the food product.”

VDG’s drum motors, Zander says, avoid that

problem by having the motor, gearbox and

all other moving components inside a sealed

box. This protects the drum motor to the

extent of giving it an IP69K washdown rating,

meaning it can be sprayed with chemical

solutions up to 3,000 psi. It also connects

directly to the belt without sprockets, avoid-

ing the crevices and gaps they create when

connected to monolithic plastic belting.

Power-transmission components present

another potential source of contamina-

tion: the oil used to lubricate them. Most

food plants use food-grade lubricants for

this purpose, but that just reduces the risk

instead of eliminating it. Key Technology

offers drives for its vibratory conveyors

with oil-free vibrating motors, which elim-

inate the gearbox and drive belts – and

their lubrication.

RIDING THE TUBE Conveyors that carry products through

tubes present unique challenges in

sanitation. Whether they use pressurized

air or physical components to move

powders and bulk solids, their enclosed

interiors are harder to access.

When such a conveyor uses disks to move

product, it presents the additional challenge

of cleaning the forward-facing surfaces of

those disks. But conveying with physical

action means that cleaning can also be

done with physical action.

Carl Seidel, marketing director for Cablevey

(www.cablevey.com), says that cleaning

out Cablevey’s disk-based conveyors with

water is an option, but one that most end

users prefer to avoid.

“For the most part, people don’t want to

introduce [water] into any kind of process-

ing environment that they don’t have to,”

Seidel says. Cleaning with water limits pro-

cessing time because it must be dried off.

Instead, Cablevey offers a urethane “pig”

that can be dragged through its tube con-

veyors to clean them out routinely with each

run or product change. More thorough clean-

ing with water can be done every week or so

with a sponge-based attachment.

An advantage of the urethane pig is that it

can accumulate fine material, such as coat-

ing particulates that fall off product particles

during conveying, and make them available

for reuse. “Material is often reclaimed, now

more than ever,” Seidel says.

Keeping conveyors sanitary is no small feat,

given their size and complicated nature. But

with the right materials and design, it can

be done routinely while maintaining effi-

ciency in material handling.

www.FoodProcessing.com

eHANDBOOK: Conveying / Sorting / Powder Bulk Handling 11

Online Configuration and Quoting at qcconveyors.com

HYDROCLEAN SERIES

• Stainless Steel, sanitary conveyor design that is NSF & BISSC Certified

• Tail flips up with easy-to-use pull pins for efficient cleaning

• Tool-less belt, drive and tail removal for in-depth cleaning

• Slider bed is self draining and fasteners are designed to reduce opportunities for bacteria growth

• Easy to integrate with other machinery

FAST, EFFICIENT

CLEANING

HC200

It is important to know before purchasing

or repurposing any pneumatic convey-

ing system, whether the powders or bulk

materials may be difficult to convey.

Although it is a challenge to move diffi-

cult powders with a pneumatic conveying

system, it is not impossible.

“Difficult powders” are materials with

poor flow properties that do not want to

move. Cohesive and lightweight powders

such as carbon black, ultra fine particles,

non-granular powders, TiO2, calcium

carbonate, and substances known in the

industry as “conveying mud” – iron oxide,

zinc oxide, and toner – are very fine, sticky

and difficult to convey at 2,000-5,000 lbs

pr/hr or (907-2,268 kg. pr/hr), rates typi-

cal in many industries.

The main challenge in moving these pow-

ders is getting them into the conveying

line from the pick-up point, feeding them

Factors to Consider When Sourcing Pneumatic Conveying Systems for Powders That Are Difficult to MoveBy Vac-U-Max

Typical VAC-U-MAX Powder-HandlingReceiver for Batch & Continuous Operation

eHANDBOOK: Conveying / Sorting / Powder Bulk Handling 13

www.FoodProcessing.com

at a constant rate, and getting the powder

to discharge from the material receiver.

Once the non-free flowing materials are

entrained, they are fluidized and convey

easily and do not build up on the convey-

ing tubes.

When non-free flowing material is intro-

duced at the pick-up point, some bulk

material may go in but it could bridge or

rat-hole at that point. If the bulk material

does not flow down into the pick-up point,

only air will be conveyed, not product.

There are several options that make it

possible to get sticky or non-free flowing

materials into a conveying line at a con-

stant rate. It is critical to have the proper

solids-to-air ratio. If it is too high, the line

will plug. If it is too low, the pneumatic

system sucks-in mainly air and does not

transport much material.

One way to enter bulk materials at a con-

stant rate is to introduce the material

into the convey line where the air flow is

mechanical, typically with a rotary valve,

or physical, typically done with a screw

feeder. Other ways to help mechanically

move the powder or bulk material, and

ensure the correct solids-to-air ratio, is

with the aid of specially devised flow

promotion devices, specifically vacuum

receivers and suitable filters placed in the

correct locations. Flow promotion devices

can be vibration on the outside of a bin or

hopper that knocks the material loose, or

a small air cannon that injects air into the

material to prevents it from sticking to the

hopper and feeder walls.

When repurposing a conveying system, a

common problem is that it will not work

with new or other bulk material. It is

important to evaluate every single powder

that is difficult to convey. Even small dif-

ferences, like processing plants that have

two locations, each using powders from

different suppliers or different grades

and material characteristcs, all may have

an impact on processing, production and

end-product quality.

There are different grades of calcium car-

bonate, which when mined from the earth,

is rocky and free-flowing. The more it is

milled down to a superfine powder, the

more cakey and sticky it gets.

Download the complete white paper here.

It is important to evaluate every single powder that is difficult to convey. Even

small differences ... may have an impact.

www.FoodProcessing.com

eHANDBOOK: Conveying / Sorting / Powder Bulk Handling 14

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Food grade conveyor systems are

necessary to automate food pro-

cessing and manufacturing plants.

Food grade conveyor systems are a crit-

ical element in the facility’s operational

efficiency and ultimately, the company’s

profitability. Conveyor technology is

advancing, and there are several things to

consider before automatically choosing to

purchase another stainless steel conveyor.

The following checklist can help you deter-

mine what type of conveyor system is

most suitable where operational efficiency

and profitability are of high importance:

EASE OF CLEANING In the food processing industry, the

ease with which you are able to clean

a conveyor system is imperative. Look

for food grade conveyor systems that

offer a simple design that is easy to take

apart for quick cleaning and sanitizing.

A good design will allow you to take

the conveyor apart without the use of

tools. Make sure all equipment parts

are accessible for cleaning and are

self-draining with no product or liquid

collection points. Consider the color of

your conveyor. Conveyor color, such as

blue, can aid in the visual identification

of soil and food particles. With the right

conveyor, you can greatly reduce your

risk of product contamination and recall.

LONGEVITY The right conveyor system will be made

of components that are chemical- and

corrosion-resistant in order to handle

the rigors of frequent cleaning and

sanitizing. Conveyor sidewalls and

product retaining walls made of plastic

will not splinter, rot or retain harmful

Food Grade Conveyor Systems: What You Should Know Before You BuyBy Dynamic Conveyor

eHANDBOOK: Conveying / Sorting / Powder Bulk Handling 16

www.FoodProcessing.com

bacteria, odors or cleaning agents.  When

made of impact resistant plastic material,

conveyor components – including

conveyor sidewalls – are cost-effective

to replace when damage is done or

conveyor design changes are needed.

COST OF OWNERSHIP Look beyond the initial purchase price

when considering the cost of the

conveyor system. Don’t forget to consider

the cost of operating and maintaining

the system. The labor and resources

needed for cleaning the conveyor can

quickly become your largest cost. Look

for a conveyor with minimal parts and the

ability to clean it quickly and efficiently.

Remember, you want your conveyor

to spend most of its time making you

money, not costing you money.

EASE OF MAINTENANCE Maintenance and uptime can affect

productivity. Determine what type of

maintenance your new system will need.

Consider motors with a hermetically

sealed design that ensures internal parts

are not exposed to external environmental

conditions and tampering. Look for

feed rollers that are bearing-free and

tensionless belts that are self-tracking.

BELTING OPTIONS Choose a vendor that offers a wide

range of belt types and styles. The

option to choose solid-surface, link

style or metal mesh belting for your

conveyor will give you ideal conveyance

of your food product whether it is dry,

wet or sticky. Look for food grade

conveyor systems that include belting

that is self-tracking, provides good

wear, performance, and service.

SAFETY As with any mechanical and electrical

device, conveyors can present some

safety concerns. Look for a conveyor

system where all of the moving parts

– such as chains, belts and sprockets –

are not accessible to fingers, hands and

loose clothing. The safest conveyors

are designed without sharp edges and

ensure that all moving parts are self-

contained or guarding is in place.

If you are still unsure which system will

serve you best, consult a conveyor expert.

Work with a conveyor manufacturer who

will partner with you to design the ideal

system for your needs.

Contact us for a free food grade conveyor

system assessment.

Download the complete white paper here.

www.FoodProcessing.com

eHANDBOOK: Conveying / Sorting / Powder Bulk Handling 17

Conveyors designed for easy and efficient cleaning and sanitizing.

231.798.1483www.DynamicConveyor.com

As food processors grew into the

20th century, the use of convey-

ors was initially thought of as a

transport method but has evolved to be

an integral part of producing large quan-

tities of food to supply an ever-growing

population. It became evident that there

was a need to streamline the handling of

food ingredients and products while uti-

lizing drums, containers, pails and mixing

equipment but the manpower required was

holding back growth. Although the use

of conveyors was initially thought of as a

transport method, they have evolved to be

an integral component to produce larger

quantities of food at quicker line speeds.

The first conveying equipment was made of

steel, aluminum, wood or whatever some-

one could muster up to do the job. Use of

cotton belting was quite common as it was

cost effective and readily available. Eventu-

ally, belt providers developed methods to

laminate covers made of a variety of resins

that allowed for cleaning the surfaces.

Although this was a major step in improving

the quality and sanitation, it wasn’t until

the introduction of new synthetic materials

which allowed for better cleaning surfaces,

strength and flexibility.

Today’s 21st century food-carrying convey-

ors have come a long way from inception.

Applications in meat and poultry, seafood,

baking, confections, fruits and vegetables,

prepared foods, frozen food and dairy-

based products have all benefited from

the newly developed conveyor designs.

But along with the benefits come capital

expense, maintenance, repairs and even

replacement, let alone government com-

pliance and stringent requirements from

food retailers.

CLEANING AND COMPLIANCE Food processing applications that store,

elevate, transfer and maintain patterns

for downstream packaging in many

cases are being utilized 24-7. Continuous

handling of the raw products can

(sometimes) create unsanitary conditions,

especially as product line demands

Evolution of Conveyors in Food ProcessingBy Multi-Conveyor

eHANDBOOK: Conveying / Sorting / Powder Bulk Handling 19

www.FoodProcessing.com

outweigh the need or time required for

regular cleaning and maintenance.

Changing of shifts, crews, contract cleaning

services and construction are some of the

issues requiring special attention to main-

tain sanitary operations. Numerous times,

the handing over from one shift to another

creates inconsistent conditions.

When agency inspectors arrive, manage-

ment should welcome any reports indicating

non-compliance as an incentive for personnel

to adhere to the sanitation standard estab-

lished and immediately comply to correct the

issues. These reports are also instrumental in

the design of future equipment, to make sure

it’s agency compliant from inception.

Belts are usually fastened at each end with

a variety of techniques. Belt splicing is done

in a variety of methods from hot vulcani-

zation, cold vulcanization or mechanical

splicing. Usually endless hot vulcanized

belts last relatively long; however, once

they require repair or replacement, the con-

veyor design becomes critical.

Many newer designs allow for the complete

disassembly of the conveyor for cleaning

using the NTR (no tools required) approach.

These designs promote time-saving belt

cleaning, repair or replacement.

NTR belt removal takes mere seconds/

minutes, allows for easy maintenance and

simplistic changeovers, alleviates unnecessary

toolboxes and tools for increased operator

safety. The tool-less pin-pull approach allows

the operator to remove the belt in mere sec-

onds for routine maintenance. 

Belt cleaning and inspection lifts are a

useful addition and are simple in design.

Additionally, lifting the belt from the bed

section allows the belt to air dry if condi-

tions allow, otherwise, belt cleaners are

commercially available. Spray heads are

another option that can use heated water

if necessary to clean the top surface and

bottom sides of the conveyor return path.

More sophisticated belt washing systems

may include dryers and programmed clean-

ing cycles with duration options.

Download the complete white paper here.

Multi-faceted sanitary washdown urethane belt conveyor for accumulating bulk unpack-aged product.

www.FoodProcessing.com

eHANDBOOK: Conveying / Sorting / Powder Bulk Handling 20

Multi-ConveyorYour best...conveyed better.www.multi-conveyor.com1-800-236-7960

ProudMember

CONVEYORSSanitary. Hygienic. CIP. Washdown.

Often copied ... never equaled.