FEATURE FOOD & BEVERAGE MAKE THE MOVE FROM FOOD-GRADE TO FOOD-SAFE


SKF says its new approach to bearing design overcomes traditional challenges and promises to transform productivity and safety in food manufacturing


W


ith a turnover of €1.1 trillion, the food and drinks industry is Europe’s


largest manufacturing sector. It is also the biggest manufacturing employer, providing livelihoods for more than 4.5 million people. Yet, food manufacturing is also an industry under strain. For the past decade, the sector’s input costs, such as materials, labour and energy, have grown by an average of 3.1% per year. Sales, meanwhile, have risen by only 2.1%, creating a downward squeeze on profits1 Those fundamentals are unlikely to


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change. Global demand for food is expected to be 60% higher by 20502


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pushing commodity prices up. The sector, which is more labour-intensive than other spheres of manufacturing, faces a continual struggle to fill vacancies. Then there’s the fast-changing nature of consumer demand, and the need to continually improve hygiene and safety standards. It’s no wonder, therefore, that European food manufacturers are increasingly looking for ways to boost productivity, cut costs, and improve manufacturing performance. In any manufacturing sector, machinery


and productivity are closely linked, which is why many food and drink players see further mechanisation and automation as an important driver of competitiveness. At around €38 billion annually, Europe’s food and drink sector invests more in capital equipment than any other part of manufacturing. But it’s not all about robots and


advanced automation systems. There are opportunities for performance improvement from changes in the design and configuration of even basic machines. Food and beverage manufacturing systems must undergo regular, thorough, washdowns to guard against the build-up of bacteria and material residues, and to avoid cross-contamination between batches, for example. But the washdown process is a drain on productivity.


The costs associated with washdowns


are not limited to the time, labour and resources required to perform them. Dowsing equipment with water and detergent can also affect its longevity and reliability. Cleaning products can find their way into bearings, for example, shortening the life of lubricants and accelerating corrosion. Managing those issues can drive up maintenance costs, either because components need more regular lubrication and attention or, worse, because problems introduced by cleaning lead to early failures and unplanned downtime. SKF recognised that overcoming these


challenges would require a different approach. So, when designing its Food Line ball bearing units – Blue Range, the company set out to produce a bearing unit that could operate without any requirement for relubrication in normal use. It’s aim was a shift in philosophy, from the use of “food-grade” components and lubricants to a design that is intrinsically “food-safe” through its entire operating life cycle. At the heart of the range is a new seal


designed to cope with repeated washdowns. Washdowns with hot water and detergent are extremely problematic for conventional bearing seals. By their nature, detergents are designed to maximise penetration, working their way into cracks and crevices to remove residues and bacterial contamination. But the characteristics that make detergent mixtures such effective cleaning agents also helps them to get past conventional bearing seals, washing out lubricant and leading to dry running or corrosion inside the bearing itself. To overcome this problem, the SKF team


turned the issue on its head. Rather than building a seal that attempts to exclude cleaning products, they developed a multi- lip sealing solution that incorporates a “gutter” design. This captures any fluid that penetrates the outer lip of the seal


The new SKF Food Line ball bearing units - Blue Range incorporates a host of innovations that address many of the long-standing issues associated with conventional bearing units


and guides it safely away. Another advantage is the housing, which


uses an over moulded rubber base seal to prevent contamination and bacteria growth between the unit and the mounting frame. A special back seal and end cover prevent process material from entering the bearing from either side, and the end cover uses a patented locking mechanism to ensure it cannot be accidentally dislodged. The geometry of the entire housing is


https://www.fooddrinkeu rope.eu/uploads/publicati ons_documents/FoodDrin kEurope_Data_and_Tren ds_2018_FINAL.pdf


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https://www.gov.uk/gove rnment/collections/industr ial-strategy-challenge- fund-joint-research-and- innovation#transforming- food-production


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designed to eliminate crevices or recesses where bacteria might establish themselves. Angled surfaces and a smooth surface finish reduce material accumulation and ensure liquids drain away easily, regardless of bearing orientation. Inside the new units, the corrosion-resistant, stainless-steel bearing rotates in long-lasting grease formulated from food-safe ingredients. All the external components of the new bearing unit are blue, making them easy to spot if a bearing is broken or parts are lost during installation or maintenance. The Blue Range’s smart external design


Expanded view of the food line ball bearings


reduces the time, water and detergent required for washdowns by 33%. Taking away the need for relubrication eliminates sources of downtime and maintenance costs. On a large conveyor system with 200 bearing units, for example, the elimination of weekly inspection and relubrication can save as much as €12,000 a year in grease and labour costs alone. Significantly, those benefits don’t mean


a compromise in terms of longevity. The bearing units can achieve a longer service life than their conventional counterparts. When they do eventually wear out, the new units have been designed for efficient recycling, with no components that require disposal in landfill.


SKF www.skf.co.uk 36 APRIL 2019 | PROCESS & CONTROL 


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