Baker Farm truck fleet runs smooth with Alemlube

As a third-generation family business, Baker Farm in the Riverina region of New South Wales is not just a farm producer. The business, which comprises Baker Farm, Baker Grain and Baker Transport, also offers contract farming services, feedlot facilities, freight, and storage of grain, hay and machinery.

To help the farm managers maintain all of their equipment in perfect condition with minimal manual work, BSC’s Wodonga branch recommended installing Alemlube Automated Lubrication Systems on the farm’s  truck fleet to automate the greasing, which helps the farm save significantly on maintenance time and costs.

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Automatic lubrication systems smooth the way for confectionery manufacturer

When an iconic confectionery manufacturer in Western Sydney had complaints about premature failure of their conveyor chains, BSC Sales Service Representative Fady Elchab recommended using Alemlube multi-point lubrication systems to auto-lubricate their chains. This resulted in extending the serviceable life of the chains by more than 100 per cent.

Fady, who regularly checks on the manufacturing plant on behalf of BSC to make sure it is well-supplied with lubricants and other consumable products, says implementing Alemlube’s auto-lubrication solution resulted in a considerable reduction in downtime and labor requirement.

“This manufacturing plant has 12 roller chain assembly lines that help run the confectionery products through various stages in the production process. The chains previously had a serviceable life of only 6-8 months. After installing Alemlube’s automatic lubricators along the line, the chains’ serviceable life has increased to as much as 12, 18, and in some cases even 24 months,” says Fady.

Auto-lubrication has also helped the plant improve operational safety by taking the manual labor out of the maintenance processes, Fady says.

“In food and beverage manufacturing, there are many applications that involve hot processes or are hard to reach for manual lubrication. In these cases we recommend using automatic lubrication systems. For example, our confectionery customer is using Alemlube automatic lubricators to lubricate the bearings in their ovens and combustion fans, which are otherwise regarded as high-risk areas for manual lubrication,” he says.

As a national supplier of industrial solutions, BSC works closely with Alemlube to bring automatic lubrication solutions to a wide range of customers, including those in the food and beverage industry.

John Knight, Alemlube’s Lubrication Systems Product Manager for Australia and New Zealand says of the many operating conditions that can cause premature component failure, few are more predominant than lack of lubrication.

“Chains, particularly in the ovens, will lock up if they are not correctly lubricated, which can cause major downtime and wear and tear,” he says.

“Bearings are also susceptible to premature failure from poor lubrication. Over half of bearing failures happen either from lack of lubrication or contamination. If bearings are kept properly lubricated and contamination-free, their life span can be improved many times over,” he says.

Alemlube multi-point lubrication systems can be designed to lubricate anywhere between 2 to 200 application points simultaneously, providing constant lubrication at desirable pressure and dosage. Among these solutions is the Pulsarlube M Series, which can be set up to lubricate up to eight lubrication dispense points with a single unit.

John says using automatic lubrication systems frees up the maintenance crew’s time to focus on other important tasks.

“When the lubrication systems are installed, the daily drudgery of greasing is taken care of. When the bearings are greased hourly by the automatic lubrication system, bearing failures become less frequent and therefore production efficiency increases. This promotes a positive feedback loop where the maintenance staff can start to focus on preventative maintenance, condition monitoring and planning instead of rushing from one breakdown to the next,” he says.

Through their partnership, the teams at BSC and Alemlube bring extensive expertise on maintenance best practices to their customers, according to John.

“The team at BSC knows and understands their customers very well. Combining this with Alemlube’s experience in design and installation of automatic lubrication systems helps address the customers’ issues related to bearing and lubrication reliability,” John says.

“Many plants tend to put production first and maintenance second. This can be detrimental to the reliability of the operations and the long-term plant health. The collaboration between BSC and Alemlube often gives the customer a new portfolio of tools and strategies to increase efficiency and reduce the costs of maintaining their plant,” he adds.

John’s views are echoed by Fady, who says both BSC and Alemlube are customer-oriented companies.

“At BSC, we are very much driven by customer satisfaction. It is quite common that I meet my customers after business hours or on weekends. That’s because I love my job and I enjoy building relationships with my customers,” he says.

“Because of this strong relationship with customers, they often call me to ask for solutions to their problems and I try my best to either help them or point them in the right direction. And the feedback that I get from customers is that they too love the support that they get from us,” Fady concludes.

Read more articles like this at: www.lets-roll.com.au

       

Poultry producer gets a set-and-forget lubrication solution

When a food processing and packaging customer within the poultry industry sought the expertise of CBC Australia to set up a new lubrication store solution for their facility, the CBC team collaborated with Alemlube and CRC Industries to meet and exceed the customer’s requirements.

CBC Australia Sales Representative, Debra Fitzpatrick, says their customer was required to meet stringent government regulations for food safety standards and environment protection.

“Understanding these requirements, we worked with our trusted partners, Alemlube and CRC Industries, to offer a set-and-forget solution that made regulatory compliance much easier for our customer,” she says.

The new lubrication store was equipped with the help of oil containers, lids, pumps and hoses provided by Alemlube, as well as a whole range of food grade oils, sealants and greases from CRC Industries. Adding a CRC SmartWasher also provided additional safety to the plant.

“CRC Industries offers a wide range of NFS H1 approved lubrication products. All of CRC’s food grade lubricants comply with Hazard Analysis and Critical Control Point (HACCP) requirements so the customer can be assured of the highest degree of safety,” says Fitzpatrick.

Cross contamination was another concern for the plant. The lubricants needed to be categorised and stored properly to avoid the risk of someone using a non-food-rated product in the food manufacturing process.

Fitzpatrick says using the Alemlube iCan range of products overcame this risk completely.

“The Alemlube products are designed to make the maintenance and upkeep of equipment easier. The lids are color coded to avoid any confusion and minimise the risk of cross contamination. The quick fill ports also help avoid foreign particle ingress during refilling,” she explains.

To further simplify the quality assurance audit processes, CBC also recommended that the customer gets on board with CRC’s Greenlight Food Safety Program.

Iain Faber, National Channel Manager at CRC Industries, says the CRC Greenlight Program incorporates extensive training with the staff in maintenance and quality assurance departments to help them achieve a high level of regulatory compliance within their plant.

“As part of the Greenlight Program, CRC offers on-site training to maintenance for use and storage of food grade lubricants and cleaners to ensure NSF certification compliance. CRC also provides the customer with an audit compliance folder, which contains TDS, SDS, Allergen certification and global NSF certification,” he says.

“As well as this, the SDS certificate is printed on the underside of the label on CRC’s Food Grade aerosols. They also come complete with the CRC Permalock straw which is a locked in straw and spray actuator that reduces the risk of contamination.”

“Moreover, CRC helps customers with product swap outs based on their technical requirements and aligns the program with the customers’ current on-site audit and inspection programs. We also offer on-going support to technical staff, chemists and field support staff via online or on-site visits.”

Representatives from CRC Industries met with the technical team at the poultry plant to take them through the required trainings and demonstrations.

The CBC team also recommended adding a CRC SmartWasher to the lubrication store as an environmentally friendly parts washing solution.

“The CRC SmartWasher has a compact design and uses the Ozzy Juice cleaning/degreasing solution for washing parts as an environmentally-friendly alternative to solvent and aqueous-based parts washers.  The Ozzy Juice is also NSF compliant as well as certified AsureQuality” says Faber.

“The SmartWasher Bioremediating Parts Washing system is both self-cleaning and safe for the user. Through the process of bioremediating, the SmartWasher constantly maintains the cleanliness of the Ozzy Juice cleaning/degreasing solution without the need for hauling away of used fluid,” he adds.

CBC’s Food and Beverage Business Development Specialist, Matthew Byrnes, says the successful delivery of the required products, as well as the subsequent recommendations by CBC for additional services to the customer, came at the back of a long-standing relationship between CBC and their customer.

“Our customers trust us to meet their operational needs for quality parts and services and we deliver that by understanding their needs – sometimes even before they arise – and always being ready with the most suitable solution,” he says.

“We have built up this reputation over many years of service to the industry and working with reliable partners. When customers ask for certain products, we don’t just deliver that particular product to them. We look at their overall process and see what can be further added to help them achieve their objectives,” he concludes.

                                                 

Poultry producer gets a set-and-forget lubrication solution

When a food processing and packaging customer within the poultry industry sought the expertise of CBC Australia to set up a new lubrication store solution for their facility, the CBC team collaborated with Alemlube and CRC Industries to meet and exceed the customer’s requirements.

CBC Australia Sales Representative, Debra Fitzpatrick, says their customer was required to meet stringent government regulations for food safety standards and environment protection.

“Understanding these requirements, we worked with our trusted partners, Alemlube and CRC Industries, to offer a set-and-forget solution that made regulatory compliance much easier for our customer,” she says.

The new lubrication store was equipped with the help of oil containers, lids, pumps and hoses provided by Alemlube, as well as a whole range of food grade oils, sealants and greases from CRC Industries. Adding a CRC SmartWasher also provided additional safety to the plant.

“CRC Industries offers a wide range of NFS H1 approved lubrication products. All of CRC’s food grade lubricants comply with Hazard Analysis and Critical Control Point (HACCP) requirements so the customer can be assured of the highest degree of safety,” says Fitzpatrick.

Cross contamination was another concern for the plant. The lubricants needed to be categorised and stored properly to avoid the risk of someone using a non-food-rated product in the food manufacturing process.

Fitzpatrick says using the Alemlube iCan range of products overcame this risk completely.

“The Alemlube products are designed to make the maintenance and upkeep of equipment easier. The lids are color coded to avoid any confusion and minimise the risk of cross contamination. The quick fill ports also help avoid foreign particle ingress during refilling,” she explains.

To further simplify the quality assurance audit processes, CBC also recommended that the customer gets on board with CRC’s Greenlight Food Safety Program.

Iain Faber, National Channel Manager at CRC Industries, says the CRC Greenlight Program incorporates extensive training with the staff in maintenance and quality assurance departments to help them achieve a high level of regulatory compliance within their plant.

“As part of the Greenlight Program, CRC offers on-site training to maintenance for use and storage of food grade lubricants and cleaners to ensure NSF certification compliance. CRC also provides the customer with an audit compliance folder, which contains TDS, SDS, Allergen certification and global NSF certification,” he says.

“As well as this, the SDS certificate is printed on the underside of the label on CRC’s Food Grade aerosols. They also come complete with the CRC Permalock straw which is a locked in straw and spray actuator that reduces the risk of contamination.”

“Moreover, CRC helps customers with product swap outs based on their technical requirements and aligns the program with the customers’ current on-site audit and inspection programs. We also offer on-going support to technical staff, chemists and field support staff via online or on-site visits.”

Representatives from CRC Industries met with the technical team at the poultry plant to take them through the required trainings and demonstrations.

The CBC team also recommended adding a CRC SmartWasher to the lubrication store as an environmentally friendly parts washing solution.

“The CRC SmartWasher has a compact design and uses the Ozzy Juice cleaning/degreasing solution for washing parts as an environmentally-friendly alternative to solvent and aqueous-based parts washers.  The Ozzy Juice is also NSF compliant as well as certified AsureQuality” says Faber.

“The SmartWasher Bioremediating Parts Washing system is both self-cleaning and safe for the user. Through the process of bioremediating, the SmartWasher constantly maintains the cleanliness of the Ozzy Juice cleaning/degreasing solution without the need for hauling away of used fluid,” he adds.

CBC’s Food and Beverage Business Development Specialist, Matthew Byrnes, says the successful delivery of the required products, as well as the subsequent recommendations by CBC for additional services to the customer, came at the back of a long-standing relationship between CBC and their customer.

“Our customers trust us to meet their operational needs for quality parts and services and we deliver that by understanding their needs – sometimes even before they arise – and always being ready with the most suitable solution,” he says.

“We have built up this reputation over many years of service to the industry and working with reliable partners. When customers ask for certain products, we don’t just deliver that particular product to them. We look at their overall process and see what can be further added to help them achieve their objectives,” he concludes.

Read more articles like this at: www.lets-roll.com.au

Smooth operators: Quality of baked goods reliant on well-lubricated equipment

The way the local bakery gets their favourite pastries and bread loaves so perfectly fluffy and moist has a lot to do with the bakery equipment used, and the smooth functioning of this equipment strongly relies on a lubrication system.

Oven chains are one of the highest cost components in any bakery operation, because the logistics of replacing them is so complex. It is both time and cost heavy to do so, requiring oven down time as well as labour time. The need to replace oven chains, however, is avoidable, because the wear and tear is usually the result of less than optimal lubrication practises.

According to Steve Keown, BSC National Product Manager for Lubricants, oven downtime in a bakery is incentive enough to invest in better lubrication systems. Keown often recommends Alemlube to customers due to the quality of their products and their history in supplying lubrication systems to the food and beverage sector.

Alemlube is a full solutions provider of lubrications systems, with the capabilities to provide off-the-shelf lubrication equipment. In an interview, Alemlube’s Lubrication Systems Product Manager, John Knight, explained that the organisation has a dedicated division which designs, installs and services the major lubrications systems integral to the food and beverage industry.

Knight passionately believes Alemlube’s automated lubrication solutions can and do increase the efficiency of bakery operations, particularly because it will mean more oven uptime.

“The logistics of oven chain replacement is daunting. It’s complicated and time consuming to conduct,” explains Knight. “The time it takes to lubricate chains by hand impacts on the productivity of the bakery and the labour cost to do this is also quite high. Lubricating the equipment automatically eliminates the labour and time needed for manual lubrication, which in turn increases productivity. The automation of this process also eliminates the risk of under or over lubrication.”

Alemlube’s BEKA Magnetic Pump Chain Lubrication System is the primary system utilised by commercial bakeries and other applications in the food and beverage sector.

It is an electric multi-shot dispensing system, oil is dispensed in small shots, with options for preferred volume of oil, with a frequency of up to 300 shots/minute possible. This method of dispensing in small quantities also minimises waste. The shots are dispensed precisely to the chain pins, without air or brushes needed.

“It makes precision lubrication of oven chains quite easy,” Knight confirms. “Keeping the oven chain in optimum fully lubricated condition reduces wear and, therefore, increases chain life. This is all made possible while the oven is in production, which is a bonus.”

According to Knight, the optimal time to lubricate the chain is during operation. Lubricating critical components during the process not only saves time, but actively reduces mechanical wear.

Other Alemlube products, such as single and multi-point lubricators, are also relevant to and suitable for installation in bakeries depending on the specific application and location.

While the lubrication of equipment is often treated as a secondary concern and the budget for it kept as minimal as possible, Knight believes it is an essential component of the smooth functioning of any machinery and equipment.

“Determining the ‘best lubrication solution’ for your machinery is hard, because optimal lubrication requires skill, time, manpower and money, but Alemlube designs their systems with the intention to make this as easy as possible.”

Alemlube automates the process of lubrication to ensure optimal lubrication of all points is maintained during production. The result is to reduce breakdowns, increase life of critical plant and to allow the redirection of maintenance resources to other tasks, such as baking.

For more information click here: www.lets-roll.com.au