Even modern retort machines can suffer interruptions in the production process, causing financial losses and damaging a company’s reputation. Surdry experts have identified three main causes of failures and provided recommendations for overcoming them.
Unplanned downtime can result in numerous substantial negative consequences for food and beverage production. Disruptions in the sterilization process can compromise product quality and safety, often leading to discarded products. Frequent interruptions can also delay the production schedule, hinder the manufacturer’s ability to meet production targets and damage the company’s reputation.
Identifying the causes behind interruptions is key to minimizing unplanned downtime while boosting equipment efficiency and profits. Surdry’s team of experts has created a guide to help manufacturers pinpoint and address these issues.
First cause: supply failure
A shortage of essentials needed for the sterilization process, including steam, air, water or electricity, is one of the most common reasons for interruptions in the sterilization process.
Solution: Before starting the sterilization process, ensure the facility is equipped with the necessary resources and that they are within optimal supply ranges. Using measuring devices at the retort’s entrance will help detect deviations. For example, Surdry equipment includes an external UPS device that allows it to continue operating during power failures. Its control system records process data and forwards it to central monitoring software once the power supply is restored.
Second cause: component failures
Deterioration and wear of critical retort components are important aspects to consider. Poor conditions can lead to unexpected downtime, with mechanical and electrical components, as well as positioning or instrumentation sensors, being the main culprits. Without an adequate stock of parts and components, manufacturers will take longer to repair machines, potentially incurring significant financial losses. Likewise, special attention must also be paid to possible leaks in the sealing elements, particularly the gasket responsible for door closure. This component often experiences the most significant wear and tear in the retort.
Solution: Establish an effective preventative maintenance (PM) plan to monitor component wear and the performance of detection and isolation mechanisms. Daily inspections of temperature sensors must be conducted to detect any deviations. In addition, it is important to maintain a reasonable stock of spare parts.
Third cause: maintenance failures
Inadequate planning and execution of preventative maintenance (PM) procedures are common causes of production interruptions. They typically result from a lack of regular support from the OEM and insufficient staff training on the retort. Studies show that manufacturers who neglect to implement an effective preventative maintenance plan can experience a drop in uptime of up to 20%, equivalent to 10 weeks per year.
Solution: Select a retort manufacturer that understands the importance of preventative maintenance and provides aftersales support programs like SurdryUP, which offers free preventative maintenance analyses. It is also crucial to adhere to OEM recommendations and establish a reliable PM plan.