Revenue Increase of $648,000 in Baking Production with Cambridge Duralite Belt
4x Longer Lifespan
Increased Production & Revenue Gains
The Challenge
A baking manufacturing facility utilizing four spiral cage systems was facing significant operational challenges due to poor belt performance. Their existing system relied on a ¾" rod-only belt, which struggled in the high-demand production environment. The belt was subjected to 100 lbs. of tension, which didn’t meet the facility’s high product volume needs, leading to frequent splicing and downtime. A total of 96 splices per year were required across the four systems with each instance of downtime resulting in an average loss of $9,000 per hour in revenue.
When calculated together, the annual revenue loss amounted to $864,000 due to production stoppages and the need for regular belt repairs.
The Solution
To address these critical issues, the facility partnered with Regal Rexnord for a solution. The Regal Rexnord team of industry and application experts recommended retrofitting the existing system with a Cambridge DuraLite® Belt. This new belt features a 400 lbs. tension rating, significantly higher than the rating of the facility’s original belt. The Duralite Belt is specifically designed to handle higher speeds and the increased throughput requirements of the production line, accommodating the facility's high product volume needs.
The Cambridge DuraLite Belt also offers the added benefit of a much longer lifespan, four times longer than the previous ¾" rods the facility was using, reducing the frequency of necessary splices and cutting down on maintenance costs. This new solution not only addressed the tension issues but also led to a more reliable and efficient production system.
The Results
By retrofitting their existing spiral systems to the Cambridge DuraLite Belt the baking facility noticed multiple significant benefits, including:
- Expert Belt Selection: The application engineers at Regal Rexnord provided expert advice and recommendations to ensure the correct belt was chosen for the specific needs of the facility, resulting in a tailored solution that directly addressed their operational challenges.
- Significant Decrease in Splice Frequency: With the Cambridge DuraLite Belt, the facility experienced a dramatic reduction in splice frequency, dropping from 96 splices per year to just 24 splices per year across the four spiral cages. This reduced the need for maintenance and minimized the disruption to production.
- Increase Production and Revenue Gains: By reducing splice frequency and minimizing downtime, the facility saw a significant reduction in lost revenue. With the reduced downtime, the company saved approximately $648,000 in lost revenue annually* (from $864,000 to $216,000), allowing for increased operational efficiency and production uptime.
* Savings are approximate and based on internal estimates. Actual results may vary.
The facility partnered with Regal Rexnord to create a customized solution utilizing the 100+ years of conveyor system and industrial automation expertise.
Conclusion
Retrofitting their existing spiral cage belts with the Cambridge DuraLite Belt delivered a robust solution for the bakery that not only resolved their belt tension issues and frequent splicing challenges but also improved the overall operational efficiency of their spiral cage systems. By partnering with Regal Rexnord, the facility was able to recover lost revenue and achieve higher productivity levels through expert belt selection recommendations, reduced downtime, and increased throughput, ensuring their continued growth and success.
Regal Rexnord provides comprehensive conveyance product solutions that help optimize your operations and support your long-term business success. As your trusted advisor, we offer decades of industry and application expertise to help you unlock peak performance in your facilities. We partner with you to understand and solve your toughest challenges and keep your systems running smoothly to extend the life of your products.
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