Meat Processing

DON'T LET DOWNTIME

CONTAMINATE YOUR PROFITS

UNNECESSARY MAINTENANCE, CONTAMINATION RISKS, WASTED ENERGY, AND INTERRUPTED PRODUCTIVITY

With the average poultry plant processing 250,000 birds daily and the average beef plant processing 5,000 head of cattle per day, it’s easy to understand the importance placed on optimizing production. Scheduled maintenance and sanitation halts processing each day at meat processing facilities. Worse yet, USDA inspectors can unexpectedly shut down your entire operation when compliance is not up to standards. It’s a constant battle occurring under ever-increasing production demands. At nearly every stage, huge barriers prevent you from optimizing performance.

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DO ANY OF THESE CHALLENGES SOUND FAMILIAR?

Time spent disassembling modular belts for cleaning.
Extreme washdown conditions wasting thousands of gallons of water.
Constant re-lubrication of roller chain drives.
Frequent replacement of V-belts that wear out faster in demanding applications.
Safety issues due to failed hose assemblies.

Food Contamination and Recalls:

Every year in the U.S., there are 75 million cases of food poisoning, and 5,000 of these cases are fatal. The U.S. Department of Agriculture (USDA) reports that 70 percent of food poisoning is caused by contaminated animal flesh.

IN 2019 THE AVERAGE POULTRY PROCESSING FACILITY LOST $486,000 IN PROFITS LOST ANNUALLY DUE TO MAINTENANCE AND DOWNTIME.

IN 2019 THE AVERAGE BEEF PROCESSING FACILITY LOST $780,000 IN LOST PROFIT DUE TO DOWNTIME OF FAILED ASSEMBLIES.

PAIN #1

Interrupted Production - Maintenance and sanitation halts processing | Up to 4-5 hours in a poultry plant = $300 per minute | Up to 8 hours in a beef plant =$500 per minute

PAIN #2

Lubrication - Risk of Unsanitary Conditions. Meat contamination due to dispersion of lubricant. USDA inspectors can instantly shut down entire meat processing lines, costing millions of dollars | Re-lubricating Downtime: 3-6 minutes per drive on average | When temperatures fall below 15ºF, Lubricants can solidify. Low temperature lubricants are more expensive | Standard working capabilities decreases by: 50% (0ºF to +14ºF) OR 66.6% (-24ºF to -1ºF) OR 75% (-39ºF to -25ºF)

PAIN #3

Wash Down - Wash down conditions wear down roller chain. Cavities and spaces for microbes to hide due to many parts. Corrosion due to chemical sanitizers | Downtime when drives break can cost up to $468,000 annual profit loss. | Thousands of dollars in water consumption each day. | Water consumption for large bird processing facility can add up to $1.3 million a year

LET GATES COST SAVING SOLUTIONS

WORK FOR YOU

LOWER PREVENTIVE MAINTENANCE

Cut back on scheduled maintenance with Gates innovative belts, hoses and couplings—products of unmatched durability and reliable performance characteristics. Examples include Poly Chain® belts that last up to three times longer than roller chain, and PosiClean®clean-in-place belts that drastically reduce time necessary for cleaning and sanitation.

DECREASE CONTAMINATION RISKS

Fight back against contamination caused by underperforming products with superior solutions that help keep your operation clean and safe. From Poly Chain® belts that require no greasy lubrication and urethane food conveyor belts made from FDA approved materials—to abrasion-resistant washdown hoses and rust-free couplings and hardware—Gates has you covered.

EFFECTIVELY MANAGE RESOURCES

Gates innovative solutions have consistently helped deliver some of the best operating efficiencies in the meat processing industry. With its smooth design, PosiClean® PC20 belting significantly reduced trim loss to increase production by $135,000 per year at a protein processing facility—all while reducing water consumption by 181,000 gallons. Imagine what Gates can do for you.

REDUCE COSTLY DOWNTIME

Conquer excessive downtime caused by retensioning, repair, washdown, abrasion and replacement. Gates comprehensive line of long-lasting power transmission, fluid power and food conveyor products helps your processing lines achieve optimal productivity in even the most demanding applications and processing environments—helping you achieve a better bottom line.

DOWNLOAD OUR PROCESS APPLICATION CHART TO SEE WHICH OF OUR PRODUCTS FITS YOUR APPLICATION NEED

PUT DOWNTIME ON THE CHOPPING BLOCK.

Food Grade Product Line: Gates food-grade belts and hose products, such as Gates TPU PosiClean conveyor belts, are USDA and NSF certified and meet the meat processing industry specifications.

Poly Chain Conversion: Replace roller chain with Poly Chain® to reduce maintenance and eliminate lubrication that could contaminate meat and poultry products.

Corrosion Resistant Hardware: Gates stainless steel hardware and sprockets are durable and allow for no rust on the product lines, less contamination to the conveying lines and easier washdown.

Energy Savings on V-belt to Synch Conversions: By converting V-belt drives to synchronous belts for fans and pumps, Gates can offer meat manufacturers 5% energy savings and reduction of downtime when it comes to sustainability.

Simplified Inventory: A system approach-hose, fittings, and crimpers for all common facility applications; including, air, water, washdown, pressure wash, and hydraulic.

Longer Life = Lower Cost of Ownership: Gates products are built to be durable and long lasting, which translates to a lower cost of ownership for your product applications.

Gates hose solutions for meat processing offer oil-resistant covers, perfect for animal fats, abrasion resistant covers, per fector washdown chemicals, and color coded options for safety measures.

Gates MegaTuff Covers are a great hose cover for meat processing environments due to a denser structure to help lock out bacteria and make cleanup easier, along with being more abrasion resistant without causing cover to be a bacteria trap.