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.
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.
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
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)
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
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.