A vegetable processor improved sanitation, reduced downtime, and boosted productivity with an engineered food-grade belt cleaner.

In a high-output food processing facility, persistent belt carryback on a key reversible conveyor was becoming a serious issue. The belt, which transported delicate vegetable products through the plant’s mixing process, was causing productivity delays, product waste, and ongoing belt mistracking.

This forced the operators to shut down the line at least once per shift for realignment and cleanup.

Like many other food manufacturers, the maintenance team tried to mitigate the carryback issues with a homemade belt cleaner that consisted of a PTFE blade attached to the conveyor. But the fix wasn’t doing the job.

With inconsistent pressure and limited contact with the belt, excess product continued to cling to the belt’s surface, fall to the floor, and build up on critical conveyor components. As the problem worsened, so did the risk of product contamination and increased maintenance downtime.

Determined to find a more effective and food-safe solution, the plant’s maintenance supervisor investigated commercial belt cleaning systems and landed on the FGP Food Grade Precleaner by Flexco. The FGP stood out for its stainless-steel design, food-grade materials, and most notably, its spring tensioner that delivers constant, controlled contact with the belt for consistent cleaning without excessive wear or risk to the splice.

 After installation, the results were immediate. Carryback was reduced dramatically, with less material accumulating on the floor and reduced fouling of pulleys and return rollers. This directly translated into fewer shutdowns, with the plant moving from a belt adjustment every shift to just once every three. That’s a 60% increase in uptime, a substantial gain for any facility focused on continuous production.

The team also reported a notable improvement in hygiene. With sanitation being non-negotiable in food handling environments, the FGP’s thoughtful design, featuring snap-on blades and tool-free maintenance, proved invaluable. The cleaner could be disassembled and cleaned quickly, without removing end plates, streamlining maintenance and reducing time spent in washdown.

Beyond improving safety and sanitation, the plant also saw a measurable productivity boost estimated at 7%. With the time saved on maintenance and the reduction in unplanned stoppages, the investment paid for itself within the first week of operation.

This case underscores the value of engineered solutions in critical food production settings. While homemade cleaning systems may offer a short-term fix, they rarely deliver the consistency, safety, or long-term performance required in modern facilities.

For this food processor, switching to a purpose-built food-grade belt cleaner didn’t just resolve a maintenance issue, it delivered operational efficiency, compliance confidence, and cleaner, safer outcomes across the board.