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Frequently Asked Questions

Find answers to common questions about our conveyor systems and services

OR see generic non-commercial advice for Engineers below

Products & Services

  • We manufacture a wide range of custom conveyor systems including belt conveyors, spiral conveyors, modular belt systems, and specialized food-grade conveyors. Each system is tailored to your specific requirements for the food processing industry.

  • We serve meat, poultry, fish, bakery, ready meals, and pharmaceutical sectors with over 30 years of specialized experience in food processing. Our expertise spans across various food production environments.

  • Custom conveyor systems are designed around your exact production process, available space, product type and throughput requirements. This can potentially improve efficiency, hygiene, operator safety and long-term reliability.

  • Our conveyors are designed to meet the highest hygiene standards and can be customized for various environments including chilled, frozen, wet processing, and cleanroom applications. All systems comply with food safety regulations.

  • Food handling and conveyor systems are widely used across poultry, meat, seafood, bakery, confectionary, dairy, ready meals, fresh produce and pet food processing facilities, helping automate movement, handling and production workflows.

  • Automation helps reduce manual handling, improve production flow, minimise downtime and increase consistency across processing lines. It can also support better traceability and improved health and safety standards.

  • Important factors include industry experience, hygienic design standards, customisation capabilities, after-sales support, installation expertise and the ability to deliver complete turnkey systems.

  • We primarily use food-grade stainless steel (304 and 316 grades) for all food contact surfaces. All materials comply with FDA and EU food safety regulations to ensure the highest hygiene standards.

  • Stainless steel conveyor systems are commonly preferred in food environments because they are durable, corrosion resistant and easier to clean, helping processors meet hygiene and food safety requirements.

  • Yes. It is common practice to offer retrofit and upgrade solutions that improve efficiency, hygiene and automation without the need to completely replace existing production lines.

  • Working with a UK manufacturer can provide faster communication, easier site support, shorter lead times and ongoing engineering assistance throughout the design, installation and servicing process.

Installation & Project Timeline

  • Project timelines vary depending on complexity, but typically range from 8-16 weeks from initial survey to final installation. We provide detailed project schedules during the planning phase to ensure transparency and proper planning.

  • Yes, we conduct comprehensive 47-point site surveys to ensure accurate project planning and quotation. This service is complimentary for serious inquiries.

  • Absolutely. We specialize in seamless integration with existing equipment and can work with various control systems and automation platforms to ensure smooth operation.

  • Project planning is important for food processing as it helps ensure conveyor systems are installed safely, efficiently and with minimal disruption to production. It also improves coordination between design, manufacturing, installation and commissioning.

  • A site survey helps identify production flow, available space, operational challenges and hygiene requirements. This allows engineers to recommend the most effective and efficient system layout for the facility.

  • In many cases, installations can be planned in phases or scheduled around production downtime to minimise disruption and maintain operational continuity wherever possible.

  • A turnkey project can include consultation, site surveys, system design, manufacturing, controls integration, installation, testing, commissioning and after-sales support.

  • Most projects follow a planned process with dedicated project management, ensuring clear communication, timeline coordination and smooth integration between manufacturing, engineering and on-site installation teams.

  • Yes. Food conveyor manufacturers should always provide experienced installation and commissioning teams to ensure equipment is correctly fitted, tested and fully operational before handover.

  • Lead times can be influenced by system complexity, factory shutdown schedules, material availability, automation requirements and the scale of on-site engineering work required.

  • Yes, we have successfully completed projects across Europe and beyond. We can manage international installations including shipping, customs, and on-site commissioning.

Training & Support

  • Regular servicing of food conveyor systems helps to maintain system performance, reduce unexpected downtime and extend the lifespan of equipment operating in demanding food production environments.

  • Yes. Wrightfield provides off-the-shelf and custom spare parts support for conveyors, live bird handling equipment and automation systems to help customers minimise downtime and maintain production continuity.

  • Lead times for replacement parts depend on the component type and availability, but dedicated spare parts support can help speed up the process for critical production equipment.

  • Preventative maintenance, routine inspections, component replacement and hygiene checks are commonly recommended to keep food processing systems operating safely and efficiently.

  • Yes. Existing systems can often be modified or upgraded to improve throughput, enhance hygiene standards or integrate new automation technologies as operations evolve.

  • Key factors include response times, engineering expertise, spare parts availability, industry experience and the ability to provide long-term support for installed systems.

  • Yes. Most servicing and maintenance tasks can be carried out on-site by experienced engineers to minimise disruption and keep production lines running efficiently.

Certifications & Warranty

  • Food equipment manufacturers should demonstrate recognised industry standards covering quality, safety, manufacturing and compliance. Certifications and accreditations help provide confidence in both the equipment and the processes used to build it.

  • Yes. Warranty terms can vary depending on the type of equipment supplied. Custom-built systems may have different warranty coverage compared to equipment supplied through third-party or reseller agreements.

  • Certified welding procedures and structural steel standards help ensure equipment is manufactured safely, consistently and to recognised engineering standards, particularly for large-scale or load-bearing systems.

  • Wrightfield operates with recognised industry accreditations including Contractor Safe, Made in Britain, EN-1090 structural steel compliance, certified welding standards and Constructionline approval.

  • Working with an accredited manufacturing partner helps provide assurance around quality control, engineering standards, site safety and regulatory compliance throughout the design, manufacture and installation process.

For Engineers & Plant Managers - Selecting the right conveyor

CONVEYOR SELECTION

  • Choosing the right food conveyor starts with the product, process and production environment rather than the conveyor itself. The main factors to consider are product characteristics, required throughput, hygiene requirements, available space, operating environment, cleaning procedures and integration with existing equipment.

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    Product weight, size, temperature, moisture content, fragility and consistency can all influence the most appropriate conveyor and belt type. The operating environment is equally important, particularly in chilled, frozen, wet or high-care food processing areas.

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    Engineers should also consider infeed and discharge heights, transfer points, line speeds, maintenance access and future increases in production.

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    A conveyor should ultimately be assessed as part of the complete processing line. Correctly matching it to upstream and downstream equipment helps prevent bottlenecks, reduce unnecessary product handling and improve long-term production efficiency.

  • A bespoke food conveyor is usually a better option when a standard conveyor cannot efficiently accommodate the product, available factory space, required throughput, hygiene requirements or existing processing equipment.

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    Standard conveyors can provide an effective and economical solution for straightforward product transfer. However, custom conveyors become particularly useful where production lines have restricted space, unusual layouts, difficult product transfers or specialist handling requirements.

    A bespoke system can be designed around existing machinery, specific infeed and discharge heights, cleaning requirements and operator access. This can reduce the need to modify other equipment or compromise the production layout.

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    The decision should therefore consider total cost of ownership rather than purchase price alone. A conveyor designed around the process can potentially improve product flow, hygiene, maintenance access and long-term operational efficiency.

  • Before replacing a conveyor, it is worth identifying why the current system is no longer meeting operational

    requirements. Common reasons include increased production volumes, changes in product type, hygiene improvements, repeated maintenance issues or new equipment being added elsewhere on the line.

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    Rather than replacing a conveyor on a like-for-like basis, it is an opportunity to review the entire production process. Small design improvements, changes in conveyor height, belt type or product transfer points can often remove bottlenecks and improve efficiency throughout the line.

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    Reviewing future production requirements during the planning stage can also help ensure the new conveyor remains suitable as the business grows.

  • Providing detailed information at the beginning of a project helps manufacturers recommend the most appropriate solution and reduces the likelihood of design changes later.

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    Useful information includes:

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    • Product type, dimensions and weight

    • Required production throughput

    • Existing equipment layout

    • Available floor space

    • Infeed and discharge heights

    • Hygiene and cleaning requirements

    • Environmental conditions such as chilled, frozen or washdown areas

    • Electrical supply requirements

    • Any future expansion plans

     

    Photographs, layout drawings and videos of the existing process can also help engineers understand the application more quickly and identify opportunities for improvement.

  • Well-designed conveyors are generally easier to maintain because critical components are more accessible and routine servicing can be completed quickly. Features such as removable belts, hygienic construction, robust bearings, quality drive systems and easily adjustable tracking all contribute to improved reliability.

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    Reducing unnecessary complexity can also minimise the number of wear components and simplify routine maintenance procedures.

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    Many production issues attributed to conveyor failure are actually caused by poor accessibility, inadequate cleaning, incorrect belt selection or difficult servicing arrangements. Considering maintenance requirements during the design stage often reduces lifetime operating costs while improving equipment availability and overall production efficiency.

Considering more hygienic conveyor designs

HYGIENE

  • Hygienic conveyor design plays a vital role in preventing food contamination and maintaining consistent product quality. Poorly designed equipment can allow food debris, moisture and bacteria to accumulate in difficult-to-clean areas, increasing the risk of microbiological growth and cross-contamination.

     

    Modern food conveyors are designed to minimise these risks by using smooth surfaces, open-frame construction where appropriate, easy-to-clean components and materials that can withstand regular washdown procedures. A hygienic design not only supports food safety but can also reduce cleaning times, improve production uptime and help manufacturers meet customer and regulatory requirements.

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    Considering hygiene during the design stage is often more effective than trying to solve cleaning challenges once equipment has been installed.

  • Stainless steel is one of the preferred materials for food conveyors because it combines excellent corrosion resistance with strength, durability and ease of cleaning. Unlike painted or coated materials, stainless steel is less likely to chip, peel or harbour bacteria when properly maintained.

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    The choice of stainless steel grade is also important. For many food processing applications, Grade 304 provides excellent performance, while Grade 316 offers increased resistance to aggressive cleaning chemicals, salt and highly corrosive environments.

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    Selecting the appropriate material depends on the application, cleaning regime and type of food being processed, rather than simply choosing the highest specification available.

  • Cleaning efficiency is often influenced by the design of the conveyor itself. Equipment with fewer enclosed sections, accessible components and removable belts allows hygiene teams to clean more effectively while reducing production downtime.

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    Features such as open-frame construction, smooth welds, sloping surfaces that encourage water drainage and easily removable wear components can all simplify routine cleaning procedures. Avoiding unnecessary horizontal surfaces and enclosed areas where food residues can collect also helps improve hygiene.

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    Reducing cleaning time not only increases production availability but can also lower labour costs and reduce water and chemical consumption.

  • The most common hygienic conveyor design problems are difficult-to-clean surfaces, inaccessible components, poor drainage, product traps and materials or components that are unsuitable for the washdown environment.

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    Typical issues include horizontal ledges where food and water can collect, enclosed sections that trap moisture, inaccessible bearings, rough or incomplete welds, hollow sections that can retain contamination and components that require excessive dismantling during cleaning.

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    Incorrect belt or component selection can also cause hygiene problems if materials deteriorate when exposed to fats, temperatures or cleaning chemicals.

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    Good hygienic design aims to make contamination visible and accessible rather than creating hidden areas that are difficult to inspect. Considering cleanability during the initial design stage can reduce cleaning time, improve hygiene and minimise production downtime.

  • The required cleaning frequency depends on the product being handled, the production environment and the manufacturer's hygiene procedures. High-risk food processing areas often require cleaning between production runs or at the end of every shift, while lower-risk applications may follow different schedules.

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    Regular inspection is just as important as cleaning. Components such as belts, rollers, bearings, guides and drive systems should be checked for wear, damage and signs of contamination. Early identification of worn or damaged parts can prevent unexpected downtime and reduce the risk of product contamination.

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    A planned cleaning and inspection programme helps maintain food safety, prolong equipment life and improve the reliability of the entire production line.

  • Selecting the right conveyor belt involves much more than choosing a material that's approved for food contact. The ideal belt should match the product being handled, the operating environment and the cleaning regime while delivering reliable performance over its service life.

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    For example, polyurethane (PU) belts are widely used for meat, poultry, dairy and bakery products because they offer a smooth, non-porous surface that's easy to clean and resistant to oils and fats. Plastic modular belts are often preferred where durability, drainage or more complex conveyor layouts are required, while wire mesh belts are commonly used in cooking, cooling and freezing applications where airflow and temperature transfer are important.

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    Engineering and plant managers should also consider factors such as belt tracking, product grip, operating temperature, chemical resistance, ease of removal for cleaning and the availability of replacement belts. Choosing the wrong belt can lead to increased wear, longer cleaning times, unnecessary downtime and higher maintenance costs.

    Rather than selecting a belt based on price alone, it's worth considering the total cost of ownership. A belt that's easier to clean, lasts longer and performs reliably can often provide significant savings throughout the lifetime of the conveyor.

General engineering considerations

ENGINEERING

  • Product build-up is one of the most common challenges in food processing, particularly when handling sticky, wet or oily products. Meat, poultry, cheese, salads and bakery products can all leave residue on conveyor belts, rollers and framework if the system is not designed for the application.

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    Reducing build-up starts with selecting the right conveyor belt and ensuring there are minimal areas where product can collect. Belt tension, scraper design, transfer points and conveyor speed can also influence how product behaves during production.

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    Regular cleaning remains essential, but a conveyor designed with hygiene in mind can significantly reduce product accumulation, shorten washdown times and improve production efficiency.

  • Transfer points are often where valuable product is lost through spillage, breakage or poor presentation. This is especially important when handling sliced meat, poultry portions, bakery products or delicate fresh produce.

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    Large gaps between conveyors, incorrect belt speeds, poorly aligned equipment and unsuitable transfer designs can all contribute to product loss.

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    Features such as tight nose transfers, correctly positioned guides and careful speed matching between conveyors help products move smoothly through the production line. Reviewing transfer points is often one of the quickest ways to improve yield while reducing waste and housekeeping.

  • Cleaning requirements should be considered at the beginning of any conveyor project rather than after installation. A conveyor that is difficult to access or dismantle can increase production downtime and make routine hygiene procedures more labour intensive.

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    Open-frame construction, removable belts, smooth welds and accessible drive components all help simplify cleaning while reducing areas where food residues can accumulate.

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    Engineering and site managers should also consider the cleaning chemicals used on site, washdown frequency and whether components can be removed without specialist tools. Good hygienic design supports food safety while improving production availability.

  • Adding a new conveyor involves much more than finding space on the factory floor. The new equipment must match the speed, height and throughput of existing machinery while maintaining smooth product flow throughout the line.

     

    Utilities such as electrical supplies, compressed air, drainage and access for maintenance should all be considered during the design phase. It is also important to ensure there is sufficient space for cleaning, servicing and future equipment upgrades.

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    Careful planning before installation can minimise disruption, reduce commissioning time and avoid costly modifications later in the project.

  • A well-designed conveyor system should do more than move products from one machine to another. It should support the entire production process by reducing manual handling, maintaining consistent product flow and minimising bottlenecks.

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    Factors such as conveyor speed, accumulation zones, transfer design, ergonomics and accessibility all influence overall line performance. Even relatively small improvements can increase throughput while reducing operator fatigue and unnecessary product handling.

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    Reviewing conveyor performance as part of the wider production line rather than as individual pieces of equipment often reveals opportunities to improve efficiency without major changes elsewhere in the factory.

What can improve conveyor reliability

RELIABILITY

  • Improving conveyor reliability starts with understanding why failures occur rather than simply replacing worn components. Many unexpected breakdowns are caused by minor issues that develop over time, such as belt misalignment, worn bearings, loose fasteners or poor lubrication practices.

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    Regular inspections, preventative maintenance and prompt replacement of worn components can significantly reduce the risk of unplanned downtime. It's also important to ensure conveyors are correctly loaded and operated within their design limits, as excessive loading or product build-up can place unnecessary strain on drive systems and moving parts.

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    Reliability should be considered throughout the equipment's lifecycle. Well-designed conveyors that are easy to inspect, clean and maintain often experience fewer failures and lower operating costs over many years.

  • Holding the right critical spare parts can dramatically reduce production downtime when unexpected failures occur. The exact requirements will vary depending on the equipment, but many food manufacturers choose to keep items such as conveyor belts, bearings, drive chains, motors, gearboxes, sensors, rollers, sprockets and pneumatic components readily available.

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    Site personnel should identify which components have the longest supplier lead times or are most likely to fail in their operating environment. Reviewing maintenance records can help determine which parts are replaced most frequently and which failures have previously caused extended downtime.

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    Developing a critical spares strategy allows maintenance teams to respond more quickly while reducing the risk of prolonged production interruptions.

  • Routine inspections are one of the most effective ways of improving conveyor reliability. While inspection frequency depends on production hours, operating conditions and the type of product being handled, visual checks are often carried out daily, with more detailed preventative maintenance completed at planned intervals.

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    Typical inspections include checking belt condition, tracking, bearing wear, chain tension, motor performance, fasteners, sensors and guarding. Early signs such as unusual noise, vibration or increased belt wear can often indicate developing faults long before a failure occurs.

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    Identifying these issues early allows maintenance to be planned during scheduled shutdowns rather than reacting to costly unplanned breakdowns.

  • Many food conveyor failures appear to happen unexpectedly during periods of peak production, but in reality they are often the result of wear that has been developing over weeks or months.

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    During busy production periods, conveyors typically operate for longer hours, carry higher product volumes and experience fewer opportunities for maintenance. Components that are already approaching the end of their service life are therefore more likely to fail under increased demand.

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    Implementing condition monitoring, preventative maintenance and planned component replacement can help reduce the likelihood of failures occurring during critical production periods.

  • An ageing food conveyor does not necessarily need replacing simply because of its age. The decision should be based on reliability, maintenance costs, hygiene, spare parts availability, production requirements and the total cost of keeping the equipment operational.

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    Repair or refurbishment may be appropriate where the conveyor remains structurally sound, replacement components are readily available and the equipment still meets production and hygiene requirements.

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    Replacement becomes more attractive when breakdowns are increasing, parts are obsolete, cleaning is difficult, capacity is restricting production or maintenance costs are continuing to rise.

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    Engineering managers should compare the cost of continued repairs and downtime against the expected operating cost and productivity benefits of replacement. In some cases, targeted upgrades to drives, belts, controls or individual conveyor sections can provide a cost-effective alternative to complete replacement.

Making the most of automation technologies

AUTOMATION

  • Automation is often considered when production demand increases, labour becomes difficult to recruit or repetitive manual tasks begin to limit throughput. However, automation isn't always about replacing people. In many cases, it allows operators to focus on higher-value activities while improving consistency and reducing product handling.

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    The best opportunities for automation are usually found where products are transferred between processes, accumulated before packing, or moved over longer distances within the factory. Before investing, it's important to understand where delays, bottlenecks or unnecessary manual intervention occur, as these often provide the greatest return on investment.

  • Yes, in many cases a new conveyor can be successfully integrated with existing machinery without replacing the entire production line. Careful planning is essential to ensure the conveyor matches the operating speeds, product flow and control systems of upstream and downstream equipment.

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    Factors such as available space, infeed and discharge heights, electrical supplies, safety systems and cleaning access should all be reviewed before installation. A well-integrated conveyor should operate as though it has always been part of the production process, helping to improve efficiency without disrupting existing operations.

  • One of the biggest causes of lost productivity is inconsistent product flow between processing stages. If one machine stops or slows down, it can quickly affect the performance of the entire production line.

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    Automation helps create a more balanced production process by controlling conveyor speeds, managing product accumulation and synchronising equipment across different stages of production. This reduces unnecessary waiting times, minimises manual intervention and helps maintain a consistent throughput from raw material to final packing.

    Reviewing product flow across the whole line, rather than focusing on individual machines, often identifies opportunities to improve efficiency with relatively small changes.

  • Before automating a food processing line, manufacturers should understand the existing process, identify bottlenecks and determine where automation will deliver a measurable operational benefit. Automating an inefficient process without addressing its underlying problems can simply make those inefficiencies happen faster.

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    Key considerations include production volumes, product characteristics, labour requirements, available space, hygiene and cleaning requirements, maintenance access and integration with existing equipment and control systems.

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    It is also important to consider what happens when production requirements change. Designing flexibility into conveyors, controls and equipment layouts can make future expansion or further automation considerably easier.

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    Successful automation should improve the overall process rather than simply replace an individual manual task. The objective may be increased throughput, greater consistency, reduced manual handling, improved safety, better product control or a combination of these factors.

  • Automation helps reduce variability by ensuring products move through the production line at controlled speeds and in a consistent manner. This can improve product presentation, reduce handling damage and maintain a steady flow between processing stages.

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    Automated controls can also monitor equipment performance, detect faults and stop or adjust sections of the line before minor issues develop into larger production problems. Combined with regular maintenance and well-designed equipment, automation supports more predictable production while helping engineering teams reduce unplanned downtime.

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    Rather than viewing automation as a single machine or conveyor, it's often most effective to see it as a way of connecting processes, improving communication between equipment and creating a more reliable manufacturing operation.

Live Bird Handling Systems - planning 

PLANNING

  • A live bird handling system is one of the most significant investments within a poultry processing facility, so careful planning at the outset can have a major impact on long-term performance.

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    Before selecting any equipment, engineering and operations teams should review current processing volumes, target throughput, factory layout, transport module design, available utilities and future production requirements. It is also important to consider bird welfare, operator safety, hygiene procedures and how the handling system will integrate with stunning, shackling or alternative processing technologies.

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    The most successful projects take a whole-line approach rather than focusing on individual machines, ensuring each stage of the process works together efficiently while allowing flexibility for future expansion.

  • Yes, in many cases a new conveyor can be successfully integrated with existing machinery without replacing the entire production line. Careful planning is essential to ensure the conveyor matches the operating speeds, product flow and control systems of upstream and downstream equipment.

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    Factors such as available space, infeed and discharge heights, electrical supplies, safety systems and cleaning access should all be reviewed before installation. A well-integrated conveyor should operate as though it has always been part of the production process, helping to improve efficiency without disrupting existing operations.

  • Selecting the correct system capacity involves more than matching current processing volumes. Engineering managers should also consider seasonal demand, future expansion plans, maintenance downtime and the capacity of downstream equipment.

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    The live bird handling system should be balanced with the rest of the processing line so that it neither restricts production nor creates unnecessary accumulation. Designing for realistic future growth often provides better long-term value than selecting equipment based solely on current production requirements.

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    Throughput should always be considered alongside bird welfare, product quality and operational efficiency rather than as an isolated performance figure.

  • Factory layout has a significant influence on the performance of a live bird handling system. Engineering teams should consider vehicle access, module unloading areas, operator movements, maintenance access, hygiene zoning and the flow of birds through the processing line.

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    Space should also be allowed for routine servicing, cleaning and future equipment upgrades. A well-planned layout helps minimise unnecessary handling, reduces congestion and supports safe working practices throughout the facility.

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    Reviewing the complete process from vehicle arrival through to stunning and processing often identifies opportunities to improve both operational efficiency and bird welfare.

  • Poultry processing facilities often evolve over many years, so flexibility should be an important consideration during the design stage.

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    You should think beyond current production requirements by considering future increases in throughput, changing transport equipment, new welfare standards, automation opportunities and potential upgrades to stunning or downstream processing systems.

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    Choosing equipment that can be expanded, reconfigured or integrated with future technologies may reduce the need for major modifications later in the system's life. Considering maintainability, spare parts availability and ongoing technical support can also help maximise the long-term value of the investment.

Live Bird Handling Systems - factory layout and logistics

A closer look at your process layout

  • The layout of a live bird handling system should be planned as part of the entire poultry processing operation rather than as a standalone installation. Engineering managers should consider how birds move through the facility from vehicle arrival and unloading through to stunning and the start of processing.

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    Important factors include available floor space, building constraints, transport module movements, operator access, hygiene zoning, maintenance access and the integration of downstream equipment. It is also worth considering future production requirements to ensure there is sufficient flexibility for expansion without major disruption.

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    A well-planned layout can improve production flow, reduce unnecessary handling and create a safer, more efficient working environment.

  • Efficient logistics help ensure birds move smoothly through each stage of the handling process while reducing delays and unnecessary manual intervention. Careful planning of vehicle movements, unloading areas, transport module storage and equipment positioning can all contribute to a more consistent production flow.

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    The team should also review potential bottlenecks where transport modules may queue or where operators are required to intervene. Simplifying movement throughout the facility can improve throughput, reduce congestion and make better use of available labour without compromising bird welfare.

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    Looking at logistics across the entire process often identifies opportunities to improve both operational efficiency and equipment utilisation.

  • Transport modules play a critical role in maintaining an efficient and predictable handling process. Their movement through the facility should minimise unnecessary waiting, manual handling and conflicting traffic routes while allowing sufficient access for inspection, cleaning and maintenance.

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    When planning module flow, engineering teams should consider unloading positions, transfer routes, storage capacity, equipment interfaces and how modules will return to the loading area after processing. The objective is to create a continuous flow that supports production while avoiding unnecessary delays or congestion.

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    A well-designed module handling process can improve throughput, reduce labour requirements and simplify day-to-day operations.

  • Every additional handling step introduces additional time, labour and complexity into the production process. A carefully planned factory layout aims to minimise unnecessary movement by positioning equipment to create a logical and continuous flow from unloading through to stunning and processing.

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    Reducing unnecessary transfers between equipment, avoiding crossing traffic routes and providing sufficient working space for operators and maintenance teams can all contribute to smoother day-to-day operation.

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    When handling processes are simplified, engineering managers often see improvements in production efficiency, maintenance access and overall equipment utilisation while supporting consistent bird handling.

  • Expanding an existing facility presents an opportunity to improve both capacity and operational efficiency, but it also requires careful planning to minimise disruption to production.

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    Site managers and personnel should assess whether existing building layouts, transport routes, utilities, hygiene zones and downstream equipment can support the increased throughput. Maintenance access, future expansion opportunities and flexibility for changing production requirements should also be considered during the design phase.

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    Taking a long-term view helps ensure new equipment integrates effectively with existing systems while providing sufficient capacity for future growth without creating new operational bottlenecks.

Live Bird Handling Systems - automation and operational efficiency

MAKING YOUR PROCESS MORE EFFICIENT

  • Automation helps create a more consistent and predictable flow throughout the live bird handling process. By reducing unnecessary manual intervention, automated systems can improve the movement of transport modules, minimise delays and help maintain a steady supply of birds to downstream processing equipment.

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    For processing and plant managers, automation is often less about replacing people and more about improving process consistency, reducing bottlenecks and allowing operators to focus on higher-value tasks. A well-designed automated system can also support better equipment utilisation while helping to maintain production targets throughout the working day.

  • Bottlenecks often occur where different parts of the production process operate at different speeds. Delays in module unloading, equipment stoppages, manual handling, poor factory layout or inconsistent product flow can all affect the performance of the entire processing line.

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    Identifying where birds or transport modules spend unnecessary time waiting is often the first step in improving operational efficiency. Reviewing the process as a complete system, rather than focusing on individual machines, helps engineering managers identify opportunities to improve throughput while reducing unnecessary handling and downtime.

  • Maintaining a smooth and continuous flow between unloading and stunning is essential for efficient poultry processing. Sudden interruptions, inconsistent module presentation or unnecessary manual intervention can reduce overall line performance and create avoidable delays.

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    Improving production flow often involves reviewing equipment synchronisation, transport module movements, conveyor speeds, control systems and communication between different stages of the process. Small improvements across multiple areas can often deliver greater benefits than major changes to a single piece of equipment.

  • Automation can help reduce the need for repetitive manual handling while improving consistency throughout the production process. Rather than replacing skilled operators, automated systems often allow employees to focus on monitoring equipment, quality control and maintenance activities instead of physically moving transport modules or repeatedly carrying out manual tasks.

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    As labour availability continues to present challenges across the food industry, many processors are reviewing where automation can improve operational efficiency while maintaining high standards of bird welfare, hygiene and production performance.

  • Measuring performance is essential for identifying opportunities to improve both equipment reliability and production efficiency. Common indicators include line throughput, equipment availability, downtime, transport module cycle times, maintenance frequency and production interruptions.

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    Many processors also monitor utility consumption, labour utilisation, planned versus unplanned maintenance and overall equipment effectiveness (OEE) to understand how efficiently the handling process is operating.

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    Regularly reviewing operational data allows engineering teams to identify trends, resolve recurring issues and make informed decisions that improve long-term production performance.

Live Bird Handling Systems - maintenance and reliability

MAINTAINING YOUR INVESTMENT

  • Preventative maintenance is one of the most effective ways of improving equipment reliability and reducing unplanned downtime. A structured maintenance programme should include regular inspection of conveyors, drive systems, chains, bearings, motors, sensors, pneumatic components and safety devices, together with routine lubrication and adjustment where required.

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    Cleaning also forms an important part of preventative maintenance, as the build-up of feathers, dust and debris can affect equipment performance over time. By installing high quality washdown systems, following planned maintenance schedules and recording recurring issues, engineering teams can identify developing faults before they result in costly production interruptions.

  • Many production stoppages are caused by relatively minor issues rather than major equipment failures. Common causes include worn bearings, damaged chains, conveyor tracking problems, failed sensors, poorly adjusted drive systems, inadequate lubrication and electrical faults.

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    Operational issues such as inconsistent transport module presentation, poor housekeeping or delayed maintenance can also reduce system reliability. Monitoring equipment performance and addressing small problems early often prevents more significant failures later, helping maintain consistent production throughout the processing day.

  • Critical spare parts for live bird handling systems typically include bearings, chains, sprockets, sensors, motors, gearboxes, pneumatic cylinders, switches and commonly used electrical control components.

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    However, the correct spares list should be based on the individual processing line rather than a generic inventory. Engineering managers should identify components that could stop production if they fail, parts with long supplier lead times and items with a known history of wear or replacement.

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    Maintenance records can help identify recurring component failures and allow minimum stock levels to be established for critical items.

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    A planned critical-spares strategy can significantly reduce recovery time following a breakdown and should form part of the wider preventative maintenance programme.

  • Reliable equipment is rarely achieved through maintenance alone. It begins with good engineering design, correct installation, routine inspections and consistent operating practices throughout the life of the system.

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    Recording maintenance history, analysing recurring faults and reviewing equipment performance can help identify opportunities for continuous improvement. Regular operator training, planned servicing and timely replacement of worn components all contribute to improved reliability while reducing lifetime operating costs.

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    A proactive approach to maintenance generally delivers better production performance than reacting to failures after they occur.

  • As equipment ages, processing managers often face the decision of whether to continue repairing existing systems or invest in upgrades. Factors to consider include increasing maintenance costs, reduced equipment reliability, difficulty obtaining spare parts, changing production requirements and opportunities to improve operational efficiency.

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    Rather than basing decisions on equipment age alone, it is useful to assess maintenance records, downtime history, equipment utilisation and the total cost of ownership. In many cases, targeted upgrades to key sections of a handling system can improve reliability and extend operational life without replacing the entire installation.

Live Bird Handling Systems - bird welfare and process optimisation

LOOKING AFTER BIRDS AND YOUR BUSINESS

  • Good bird welfare begins long before the stunning process. Engineering design plays an important role in creating a calm, consistent and predictable journey from unloading through to processing.

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    Factors such as factory layout, transport module movement, equipment reliability and the number of handling stages can all influence how smoothly birds move through the facility. Reducing unnecessary stops, delays and manual intervention helps create a more controlled process while supporting operational efficiency.

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    When welfare is considered during the design stage, engineering teams can often improve both production performance and the overall handling process.

  • Every additional handling step introduces more time, labour and complexity into the production process. Reducing unnecessary handling not only supports bird welfare but can also improve production efficiency and reduce manual intervention.

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    Engineering and processing managers should review the complete handling process, looking for opportunities to simplify transport module movements, eliminate unnecessary transfers and improve equipment integration. Automation, efficient layouts and well-planned production flow can all contribute to reducing handling while maintaining consistent throughput.

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    The objective should always be to create a smooth, continuous process from arrival through to stunning.

  • Maintaining a steady flow throughout the live bird handling process helps reduce unnecessary waiting, minimise interruptions and improve the utilisation of downstream equipment.

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    From an engineering perspective, consistent flow reduces the likelihood of bottlenecks and repeated stop-start operation, allowing equipment to perform more efficiently. It also helps create a more predictable handling process, supporting both operational performance and bird welfare.

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    Rather than focusing solely on throughput, engineering teams should aim for a balanced production process where each stage operates at a consistent and controlled pace.

  • The best operational improvements often come from collaboration between engineering, production and welfare teams. While engineering managers focus on equipment performance and reliability, welfare teams provide valuable insight into how handling practices affect birds throughout the production process.

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    Regular reviews of production data, maintenance records, handling observations and equipment performance can help identify opportunities for continuous improvement. By working together, different departments can often resolve operational challenges that improve both welfare outcomes and production efficiency.

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    A collaborative approach helps ensure that equipment and operating procedures continue to evolve alongside changing industry expectations.

  • Process optimisation is about improving how every stage of the production line works together. Small improvements in equipment reliability, production flow, factory layout and automation can reduce unnecessary delays, improve equipment utilisation and create a more consistent handling process.

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    Processing plant managers often focus on throughput and reliability, while welfare teams concentrate on bird handling and process consistency. In practice, these objectives are closely linked. A production line that operates smoothly, with minimal interruptions and well-maintained equipment, is generally better positioned to support both efficient production and positive welfare outcomes.

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    Continuous improvement should therefore be viewed as an ongoing process that benefits the entire operation rather than a one-off engineering project.

Live Bird Stunning Systems - your process environment

WHAT'S RIGHT FOR YOUR PROCESS?

  • Choosing the right poultry stunning system requires comparison of bird welfare, throughput, factory layout, operating costs, utilities, maintenance requirements, labour and integration with existing live bird handling equipment.

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    The main technologies used commercially include electrical waterbath stunning, controlled atmosphere stunning (CAS) using gas, and Low Atmospheric Pressure Stunning (LAPS), which uses a gradual reduction in atmospheric pressure.

    Each technology has different infrastructure, utility, maintenance and operating requirements, so there is no single solution that is appropriate for every processing plant.

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    Processors should compare both capital expenditure and total cost of ownership, including energy or gas consumption, servicing, spare parts, equipment availability and expected operational life. Future production volumes, changing welfare requirements and the ability to integrate with existing or future equipment should also form part of the decision.

  • Several stunning methods are used within the poultry processing industry, each offering different operational characteristics.

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    Electrical waterbath stunning has been widely adopted for many years and remains common in many processing plants. Controlled atmosphere systems (CAS) use carefully managed gas mixtures to render birds unconscious before processing. Low Atmospheric Pressure Stunning (LAPS) is another technology that achieves unconsciousness by gradually reducing atmospheric pressure within a sealed chamber rather than using gas.

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    Each method has different infrastructure requirements, operating procedures and welfare considerations. Understanding how each technology works, together with its practical implications for the processing line, can help engineering teams make informed decisions when planning future investments.

  • When comparing stunning technologies, it's useful to look beyond the initial purchase cost. Engineering managers should assess how each system performs across a range of operational and practical considerations.

    These may include:

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    • Bird welfare

    • Processing throughput

    • Integration with existing live bird handling equipment

    • Energy and utility requirements

    • Operating costs

    • Cleaning and maintenance

    • Reliability and uptime

    • Available factory space

    • Future expansion opportunities

    • Regulatory and customer requirements

     

    Considering the total cost of ownership over the expected life of the equipment often provides a more accurate basis for comparison than capital cost alone.

  • Many existing poultry processing plants have successfully upgraded or changed their stunning technology as production requirements, welfare standards and customer expectations have evolved.

     

    Before making any changes, engineering teams should assess how a new stunning system will integrate with existing live bird handling equipment, transport modules, conveyors and downstream processing machinery. Building layout, utilities, production capacity and installation planning should also be reviewed.

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    Early feasibility studies and detailed site surveys can help identify opportunities and potential challenges before major investment decisions are made.

  • Poultry processing facilities are long-term investments, so selecting a stunning system should take future requirements into account as well as current production needs.

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    Site managers should consider anticipated increases in throughput, changing welfare standards, customer expectations, energy efficiency, maintenance requirements and the ability to integrate with future automation or live bird handling technologies.

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    Choosing equipment that can adapt to changing production demands may reduce the need for major modifications later and help protect the long-term value of the investment.

Live Bird Stunning Systems - bird welfare and handling

BIRD WELFARE/HANDLING

  • Bird welfare is influenced by the entire handling process rather than the stunning system alone. From the moment birds arrive at the processing plant, factors such as transport conditions, waiting times, environmental temperature, handling practices and equipment design all play an important role.

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    A well-designed live bird handling process aims to minimise unnecessary movement and handling while maintaining a calm, consistent flow through the plant. Engineering considerations such as smooth module transfer, reliable conveyors and well-maintained equipment also help reduce unnecessary delays that may increase stress.

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    Looking at the complete journey rather than a single stage of the process is often the most effective way of supporting both bird welfare and operational efficiency.

  • Automation can improve consistency by reducing unnecessary manual handling and helping birds move through the processing process in a controlled and predictable manner. Automated handling systems can also reduce repetitive manual tasks for operators while maintaining a steady flow of transport modules and drawers.

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    Consistency is often one of the biggest advantages of automation. Equipment operating within defined parameters is able to repeat the same movements throughout the production day, helping to reduce variation that may occur with manual handling alone.

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    Successful automation should always be viewed as supporting good stockmanship and operational practices rather than replacing them.

  • Every additional handling step has the potential to increase stress, extend processing time and introduce unnecessary complexity into the production process. Reviewing how birds move from transport modules through to the stunning stage can often identify opportunities to simplify the overall handling sequence.

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    Processing facility managers should consider whether equipment layout, module movement, transfer points and production flow can be improved to reduce unnecessary intervention. Well-planned automation and efficient factory layouts can help create a smoother process while supporting both operational performance and bird welfare.

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    Reducing handling should be considered alongside operator safety, equipment reliability and production efficiency as part of the overall system design.

  • Yes. Factory layout can have a significant impact on both operational efficiency and bird welfare. Poorly planned layouts may create unnecessary waiting times, repeated handling or congestion between different stages of the process.

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    When planning a new installation or upgrading an existing facility, engineering teams should consider vehicle access, unloading areas, transport module movement, equipment spacing, maintenance access and how birds progress through the plant.

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    Designing the process to maintain a smooth, continuous flow can help reduce delays while improving efficiency throughout the processing line.

  • Bird welfare should be monitored as an ongoing process rather than through occasional reviews. Site managers can track key welfare indicators at different stages of handling and processing, alongside operational data such as waiting times, equipment stoppages, line speeds and handling interventions.

     

    Regular observations can help identify patterns or changes that may indicate areas for improvement.

    Engineering, production and welfare teams should review this information together, as equipment performance and bird welfare are often closely linked. Recurring delays, inconsistent product flow or equipment faults may affect both welfare outcomes and processing efficiency.

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    Routine equipment inspections, staff training and analysis of welfare and production records can help identify trends over time. Where issues are identified, adjustments to equipment, factory layout, operating procedures or maintenance schedules can then be assessed and their impact measured. This continuous improvement approach helps processors maintain consistent welfare standards while improving the reliability and efficiency of the overall handling process.

Live Bird Stunning Systems - operational efficiency

WHAT MAKES AN EFFICIENT PROCESS?

  • The operating cost of a poultry stunning system should be compared using total cost of ownership rather than energy consumption or purchase price alone.

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    Important costs include electricity, gas or other consumables, labour, preventative maintenance, spare parts, servicing, cleaning, equipment downtime and expected service life.

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    Different stunning technologies have different cost structures. Controlled atmosphere systems require a continuing supply of process gas, while electrical and low atmospheric pressure systems have different electrical, mechanical and maintenance requirements.

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    Changes in electricity and gas prices can therefore affect technologies differently over the lifetime of an installation. Processors should model these costs against expected throughput and equipment utilisation to understand the likely cost per bird and the sensitivity of operating costs to future utility-price changes.

  • Utility costs have become an increasingly important consideration for poultry processors, particularly during periods of energy market volatility. Technologies that rely on consumable gases may experience changing operating costs as market prices fluctuate, making long-term budgeting more challenging.

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    Engineering managers should consider how future changes in electricity, gas and other utilities could affect production costs over the expected life of the equipment. Some processing technologies rely primarily on electrical power, while others require a combination of electricity and consumable gases.

    Understanding how different systems use utilities can help processors evaluate long-term operational resilience alongside throughput, welfare and maintenance requirements.

  • A comprehensive cost assessment should extend well beyond the purchase price. Factors such as installation, commissioning, utilities, preventative maintenance, servicing, consumables, spare parts, operator training and equipment availability all contribute to the lifetime cost of a processing system.

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    Potential downtime, production efficiency and future upgrade requirements should also be considered, as these may have a greater financial impact over the life of the equipment than the original capital investment.

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    Evaluating the full operational lifecycle helps processors compare different technologies on a consistent and informed basis.

  • Automation can improve operational efficiency by creating a more consistent and predictable production flow throughout the processing plant. Automated handling systems can reduce unnecessary manual intervention, improve equipment synchronisation and help minimise bottlenecks between different stages of production.

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    Consistent module handling, controlled product flow and reliable equipment operation can also support better utilisation of downstream processing equipment while reducing unplanned interruptions.

    When viewed as part of the complete production process, automation often contributes to improved throughput, more consistent operating performance and better long-term equipment utilisation.

  • Modern poultry processing facilities are expected to respond to changing customer expectations, evolving welfare standards, labour availability and fluctuations in utility costs. Building resilience into a processing line means considering not only today's production requirements but also future operational challenges.

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    Flexible equipment layouts, reliable automation, preventative maintenance programmes and systems that can adapt to changing production demands all contribute to long-term resilience. Engineering managers may also evaluate how different technologies rely on utilities such as electricity, compressed air or consumable gases, particularly where supply security or market volatility could influence operating costs over time.

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    Taking a long-term view during project planning can help reduce future operating risks while supporting efficient, sustainable production.

Live Bird Stunning Systems - maintenance & reliability

IMPROVING PROCESS RELIABILITY

  • Preventative maintenance is one of the most effective ways of maintaining equipment reliability and avoiding unplanned production stoppages. Every stunning system will have its own maintenance requirements, but regular inspections should include moving components, conveyors, sensors, drive systems, pneumatic equipment, electrical connections and safety devices.

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    Routine cleaning is equally important, as the build-up of dust, feathers or other debris can affect equipment performance over time. Following the manufacturer's maintenance schedule, combined with regular inspections by trained engineers, helps identify wear before it develops into a more significant failure.

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    A planned maintenance programme not only improves reliability but also supports consistent production and extends the working life of the equipment.

  • Many production stoppages are not caused by major equipment failures but by relatively small issues that have developed over time. Worn components, poor adjustment, inadequate lubrication, damaged sensors, conveyor faults or missed preventative maintenance can all contribute to unexpected downtime.

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    Operational factors such as inconsistent module presentation, poor housekeeping or equipment operating outside its intended capacity can also affect system reliability.

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    Monitoring equipment performance and addressing minor issues early is often the most effective way of reducing production interruptions and maintaining consistent throughput.

  • Holding the right critical spare parts can significantly reduce recovery time when equipment failures occur. The most appropriate stock will depend on the type of live bird handling and stunning system installed, but many processors keep commonly used wear components, sensors, motors, gearboxes, bearings, chains, pneumatic parts and electrical control components readily available. 

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    Engineering managers and site managers should review maintenance records and supplier lead times to identify components that are both critical to production and difficult to replace at short notice.

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    A well-planned critical spares strategy helps reduce downtime while supporting more effective maintenance planning.

  • Reliability is rarely achieved through maintenance alone. It begins with good system design, appropriate equipment selection and effective operational practices.

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    Regular preventative maintenance, routine inspections, operator training and accurate maintenance records all contribute to improved equipment reliability. It is also important to monitor recurring faults, as repeated failures may indicate an underlying engineering issue rather than isolated component wear.

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    Taking a continuous improvement approach allows engineering teams to identify opportunities to improve equipment performance while reducing lifetime operating costs.

  • As poultry stunning and processing equipment ages, engineering and site managers may reach a point where repeated repairs become less cost-effective than upgrading part or all of the system. Increasing maintenance costs, difficulty obtaining spare parts, reduced reliability, lower production efficiency and changing operational requirements can all indicate that an upgrade should be considered.

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    Rather than making decisions based solely on equipment age, it is often more useful to assess maintenance history, equipment availability, future production requirements and the total cost of ownership.

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    A structured review of these factors helps processors determine whether refurbishment, partial upgrades or complete replacement will deliver the greatest long-term value.

Live Bird Stunning Systems - sustainability & planning

MAKING YOUR PROCESS SUSTAINABLE

  • Poultry processors can reduce environmental impact by focusing on energy consumption, water use, waste, emissions, consumables and overall production efficiency across the complete processing line.

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    The first step is usually to measure where resources are being consumed. This can include electricity used by motors and refrigeration, water used for cleaning, compressed air, process gases, waste streams and production losses.

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    Equipment efficiency is only part of the solution. Preventative maintenance, improved production flow, reduced downtime, effective automation and appropriate cleaning procedures can all reduce unnecessary resource consumption.

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    When investing in new processing equipment, managers should consider lifetime energy and utility requirements alongside throughput, reliability, maintainability and capital cost. This allows environmental performance and operational efficiency to be assessed together rather than as separate objectives.

  • Utility consumption should be considered as it is an important part of the long-term operating cost of any poultry processing and stunning facility. Different stunning technologies have different utility requirements, with some relying primarily on electrical power and others requiring additional consumables such as gases.

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    As energy markets continue to fluctuate, managers increasingly evaluate how equipment choices may affect operational costs over many years. Considering utility requirements during the planning stage can provide a better understanding of future operating expenditure while helping businesses improve long-term resilience and budgeting.

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    Utility consumption should always be assessed alongside throughput, welfare, reliability and maintenance when comparing processing technologies.

  • Environmental legislation and customer sustainability expectations continue to evolve, making long-term planning increasingly important for poultry processors.

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    When investing in new equipment, engineering managers should consider factors such as energy efficiency, utility consumption, emissions, maintainability and the ability to integrate future technologies. Flexible processing lines that can adapt to changing operational or environmental requirements are often better positioned to meet future regulatory and commercial demands.

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    Considering sustainability at the design stage may also reduce the need for more significant modifications later in the equipment's lifecycle.

  • Reducing costs for Engineering Managers involves much more than lowering energy consumption. Reliable equipment, preventative maintenance, efficient production flow, reduced downtime and effective automation can all contribute to lower lifetime operating costs.

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    Utility usage should also be reviewed as part of a wider assessment of operational efficiency. Some technologies require ongoing consumables in addition to electrical power, while others rely primarily on electricity alone. Understanding these differences allows engineering teams to evaluate long-term running costs alongside maintenance, servicing and production performance.

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    Taking a total cost of ownership approach often provides a more accurate picture than comparing capital investment alone.

  • Sustainability is no longer viewed solely as an environmental objective. Many of the improvements that reduce environmental impact also contribute to lower operating costs and more efficient production.

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    Reducing energy consumption, minimising waste, improving equipment reliability and increasing production efficiency can all support both environmental goals and commercial performance.

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    Site managers are therefore increasingly assessing equipment not only on throughput and reliability but also on how efficiently it uses resources throughout its operational life.

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    By considering environmental performance alongside productivity, processors can develop facilities that are more resilient, adaptable and better prepared for future market and regulatory changes.

Custom Food Conveyor Systems vs off the shelf conveyors

WHAT'S BEST FOR YOUR PROCESS

  • An off-the-shelf conveyor is generally supplied in standard sizes and configurations, making it suitable for straightforward product movement applications.

     

    A custom conveyor is designed around a specific production process, taking into account factors such as available space, product type, throughput, hygiene requirements, existing machinery and operator access.

     

    Custom conveyors are particularly useful where standard equipment would require the production process or factory layout to be adapted around it.

  • A custom conveyor should be considered when standard equipment cannot easily meet the requirements of the production process.

     

    Common reasons include restricted factory space, unusual conveyor routes, specific infeed or discharge heights, hygiene requirements, difficult product transfers, high throughput or the need to integrate with existing processing and packaging machinery.

     

    For simple applications with few constraints, a standard conveyor may still be the most cost-effective choice.

  • Custom food conveyors can have a higher initial cost because they require additional design and engineering. However, purchase price should be considered alongside installation, modifications, downtime, cleaning, maintenance, product waste and future production requirements.

     

    A standard conveyor that requires surrounding equipment or factory layouts to be modified can sometimes have a higher overall cost than equipment designed specifically for the application.

  • The main benefit of a bespoke conveyor is that it can be designed around the production process rather than requiring the process to fit around standard equipment.

     

    This can improve use of available space, product flow, hygiene, cleaning access, maintenance, operator access and integration with other machinery. Customisation can also help manufacturers accommodate unusual products, challenging transfers and future changes in production requirements.

  • Yes. Custom conveyors are frequently designed to integrate with existing processing, weighing, inspection and packaging equipment. The design can take account of existing infeed and discharge heights, conveyor speeds, product transfers, available space and control requirements.

     

    A site survey and accurate production-line information can help identify potential integration issues before manufacturing begins.

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