Moving hygienic belting forward

A Head-to-Head with Saint-Gobain and Sandvik

Food Solutions asks Ian Hutcheson, Marketing & Development Manager at Saint-Gobain Performance Plastics and Staffan Karlsson, Mechanical Engineer at Sandvik about new technologies, key developments and improving profitability in the hygienic conveyors and belting sector.

“The most significant development in recent years has been the use of pre-welded endless belts, making processing cleaner, safer and faster”
-Staffan Karlsson

FS. Demands on hygienic conveyors and belting in the food industry are constantly increasing and the focus is increasingly aimed at clean design and operation. How has this changed the needs of companies when it comes to their processing and packaging lines and how have you responded to these trends in your offerings?
IH. The key drivers in our experience have been threefold. Firstly, food processors are increasingly looking for high temperature, non-stick easy release process conveyor belts or release sheets that minimise the build-up of any food contamination and do not support bacterial growth. Secondly, processors want products that are easily cleaned and suitable for use in a wide range of cooking conditions and processes. Thirdly, they want products that are robust and economical but can be replaced easily and at reasonable cost if mechanically damaged. While Saint-Gobain’s traditional expertise has been in PTFE-coated fabrics that work up to continuous temperatures of 260°C, we have developed unique PTFE-film fabric laminates which ensure superior non-stick performance, easier cleaning and avoid build-up of food residues on the belt surface. Saint-Gobain has also expanded its range to include high strength PTFE-fabrics that are extremely durable in steam and moist environments.

SK. Stainless steel has always been the best choice for hygienic and safe handling of bacteria sensitive products in both medical and food-related applications. Our focus has always been – and remains – on enabling fast, easy cleaning of conveying belts and associated equipment.

FS. In what ways have new technologies been incorporated into the operation and management of processing and packaging lines, and what advantages has this development brought?
IH. The use of PTFE-fabrics as high temperature, non-stick food process conveyor belts has been a relatively recent phenomenon and the extent of their usage has increased significantly over the last 10 years. This reflects on the increased availability and use of simple electronic guiding systems that ensure the belts are kept in position and tracking smoothly and mechanical damage is avoided. Secondly, the versatility of PTFE-fabrics in terms of their ability to work in different cooking processes ranging from contact grilling using radiant heat, to steam cookers and microwave or hot air drying tunnels has allowed in certain cases, for these technologies to be combined in the one machine and hereby facilitated higher productivity, better quality and more appealing food products.

SK. T he most significant development in recent years has been the use of pre-welded endless belts, making processing cleaner, safer and faster. We work closely with OEMs in this sector to get across to end users the unique hygienic benefits of stainless steel, and the development of pre-welded endless belts has only served to strengthen the case for stainless.

FS. Improving profitability is an ongoing aim for business in general, and especially so in this competitive market. How can the right production line technologies help companies to achieve such an aim?
IH. The key benefit of any process conveyor belt and cooking system is that it facilitates continuous production and hereby increases productivity as well as making it easier to establish and maintain the same processing parameters in ongoing production. We have worked with OEMs, food processors and major quick service restaurants to turn batch toasting, grilling, baking and vacuum drying operations into continuous processes where the product is processed with a minimum of handling and conditions are kept at pre-determined settings to ensure it is properly cooked. Our CHEMFAB laminated belting products have good steam resistance and this facilitates their use with continuous hot water cleaning systems for a more hygienic environment. Our work with the Swedish based OEM, Formcook, who have developed continuous contact grilling lines for meat, fish and vegetable cooking, has allowed many processors to improve their output and profits significantly since we first started our co-operation 20 years ago.

SK. The safe production and transportation of sensitive foodstuffs is central to a business’s survival as well as its profitability; the fact that a company can point to its processes and demonstrate its impeccable standards of hygiene is a powerful marketing tool. Furthermore, our worldwide presence and service means we’re able to provide a rapid response to service calls and therefore maximise uptime, productivity and, ultimately, bottom line profitability.

FS. Reducing downtime and adhering to tougher sanitation and hygiene standards have caused many companies to upgrade their processing lines. How do you see the industry evolving to meet these and other challenges? What will be the key developments over the next couple of years?
IH. It is clear that the standards will become more demanding over time. I see three major changes. Firstly, the industry will increasingly demand confirmation that all materials being used in contact with food comply with the most demanding regulations and standards. Secondly, there will be an increased emphasis on regular cleaning and materials that are easy-to-clean and still retain their various physical properties throughout their lifetime. Thirdly, there will be an ongoing shift to continuous processing lines with increased levels of process control to ensure that the desired recipe and processes are followed exactly and consistently. This also means taking raw food ingredients through the preparation, cooking and cooling processes and onto the packing stations with a minimum of interruption and manual intervention. In Saint-Gobain’s case, we are working to develop products with even better non-stick properties and with improved abrasion resistance so that the useful lifetimes are further improved.

SK. A move to stainless steel belts for food processing or transporting delivers an immediate upgrade from the point of view of sanitation. Add in the benefits of greater system availability due to lower maintenance requirements and faster, easier cleaning, plus of course the much longer working life and it’s not difficult to see where the industry is going.

And, it has to be said, increasing concern over diseases such as BSE and avian influenza is only going to accelerate the move to stainless steel-based processing.

FS. How do your belting solutions reduce the areas where bacteria can hibernate and grow?
IH. Saint-Gobain CHEMFAB belts have a number of unique advantages as they are constructed from PTFE-fabric (Teflon) laminates where the fabric which gives the conveyor belt the necessary mechanical robustness is fully encapsulated in a multilayer cast PTFE film that ensure a crack-free and non-stick surface. Therefore, the belt surface will not support bacterial growth and there are no micro-cracks or pores where build-up can occur. The non-stick, low co-efficient of friction surface also means that it is very easy to clean any food residues after processing is complete or when products and recipes are changed. With the cleaned belt, one avoids any concerns of bacterial contamination and any negative impact on taste. Finally, CHEMFAB high performance belts are suitable for continuous use up to temperatures of 260°C and obviously at these temperatures it is easy to ensure that all bacteria present in the raw material food ingredients have been fully destroyed.

SK. That’s an easy one to answer: a pre-welded solid steel belt has no joints in which bacteria can develop and no fibres in which germs can collect.