Case Study: Emergency Repair of Vibratory Conveyors
Client: Frozen Vegetable Processor
Equipment: Three Vibratory Conveyors, originally manufactured by another manufucaturer
Product: Frozen Peas
Problem: A hole formed in the conveyor trays due to leaf spring block failure
Response Time: Call received at 9:34am on Monday, the job was completed at 2pm the next day
Background
During the short, critical frozen pea production window, just three months annually, the client experienced unexpected failures in three vibratory conveyors.
Each conveyor developed a hole in its tray caused by a block failure on the leaf springs. This posed a significant risk of production loss during the vital manufacturing period.
Challenge
The repair team faced an extremely tight six-hour window to complete the work and return the conveyors to full operation. With the frozen pea production season lasting only three months, any loss of processing time risked significant financial and supply chain impacts. The task was further complicated by the need for precision grinding, welding, and cleaning to exacting food-grade standards, all within the production facility. Root cause analysis revealed that excessive vibration amplitude, caused by a leaf spring block failure, had greatly accelerated wear and ultimately led to tray perforation.
Action Taken
Rapid shutdown and triage
Service engineers quickly assessed the damage on all three conveyors, prioritising repairs based on severity.
Preparation and handling of materials
The damaged pieces of the tray were ground out so that all weakened metal edges could be eliminated, and a clean area was created to add the repair plates.
Welding and repairing
New plates were welded onto the trays, restoring structural integrity while ensuring compliance with food safety standards.
Cleaning and system verification
Post-weld, all conveyors were thoroughly cleaned to remove any debris or contaminants. Then the conveyors were carefully tested under operational conditions.
Outcome
The repair was completed within the 6-hour window, minimising downtime and ensuring uninterrupted seasonal frozen pea production. The conveyors were fully restored to operational condition, with reinforced trays designed to withstand vibration stresses. The client expressed their appreciation for the swift turnaround and the team’s strong commitment to maintaining hygiene standards throughout the process.