Challenge and Outcome: Doughnut Mesh Conveyor For Production Line

Wrightfield delivered a bespoke conveyor solution for a doughnut production facility in Latvia, working in partnership with Starfrost. The project required product to be transferred directly from a production line up to the infeed of a spiral cooling system.

The key challenge was managing a significant height difference — moving product from floor level to approximately four metres — while also accommodating a non-standard layout. Unlike typical spiral systems, where both infeed and outfeed heights are aligned, this installation required the outfeed packing area to remain at a lower level due to space constraints. This introduced additional complexity in both elevation and system design.

In addition to the vertical movement, the system also required a 90-degree directional change. Due to the size of the doughnuts and the belt widths required, a direct transfer between conveyor types would have created an unreliable transfer point. Differences in roller diameters between the incline belt and the wire radius belt would have resulted in large gaps, increasing the risk of product damage.

To overcome this, Wrightfield engineered a multi-stage solution. An incline conveyor lifted the product to the required height, followed by a dedicated transfer conveyor to bridge the gap between systems. This allowed for a smooth transition onto a wire belt radius conveyor, enabling the 90-degree change in direction.

A critical aspect of the design was protecting the integrity of the product. The doughnuts, often coated in chocolate or toppings, needed to remain stable throughout the process. Any tipping, dropping, or misalignment could result in product damage or quality issues. The inclusion of the transfer conveyor ensured minimal drop points and controlled movement, preventing flipping or disruption to the product surface.

The project included full site survey, design, and manufacture, with the system supplied for installation on site. The result was a reliable, efficient conveyor solution tailored to both the product and the constraints of the facility.