CASE STUDY
Expertise, stainless steel solutions and hands-on collaboration delivered results at a large food processing facility.
Challenge
At a large food processing facility, corrosion and water ingress of electrical components caused frequent, ongoing failures in washdown applications. These failures led to unplanned downtime, increased maintenance and production delays. Every minute of downtime was costly at this facility, but the concern extended beyond the financial impact. For a global food company that prides itself on making quality food and bringing value to its customers and communities, operational continuity at facilities is critical to meeting that commitment.
In food processing environments, unplanned downtime can be extremely costly. Industry estimates suggest downtime can exceed $30,000 per hour, with full facility shutdowns significantly higher.1 Frequent component replacement also adds recurring maintenance costs and disrupts operations.
Solution
Wesco and ABB partnered to address the washdown failures at the facility. First, the ABB Installation Products Mobile Solutions Truck was brought on-site to showcase stainless steel solutions that were available to the customer. More than 50 of the facility’s engineering, maintenance and operations team members engaged in a hands-on demonstration of washdown-rated solutions. The team members were able to see the ABB T&B® Liquidtight® Type A technology and experience its superior corrosion and ingress protection firsthand. They were also able to check out the wide variety of Liquidtight material and configuration options available.
Summary
- More than 50 team members were educated on new washdown technology
- Plan to convert 70% of facility washdown areas to the new ABB solution
- Reduced failures caused by water ingress and corrosion
- Improved uptime and reliability
- Decreased maintenance time and cost
Next, Wesco and ABB conducted a walk-through, checking the fittings and connections used throughout the plant. There were multiple areas with carbon steel or plastic fittings. Fittings with these materials were at risk for premature failure, which would allow water into the electrical components in washdown applications. It was noted that this facility performed washdown and sanitation seven days a week, using a different chemical each day to prevent bacteria from becoming chemical resistant. The frequency of washdowns, the variance in chemicals and the hot water temperature required for food processing necessitated stainless steel electrical fittings. Based on these findings, Wesco and ABB technical experts were able to help the facility find the right ABB T&B® Liquidtight® fittings and hoses to provide the best results for its specific washdown applications. The recommended solutions aligned with the requirements of harsh washdown environments, including UL4X and IP69 ratings.
Learn more about ABB Installation Products solutions for washdown environments.
Results
The new stainless steel ABB T&B Liquidtight solution has proven to last. It has greatly reduced failures caused by water ingress and corrosion, improved uptime and reliability in sanitation-critical zones, and decreased turnover within the facility’s vendor managed inventory program. The facility is in the process of changing 70% of its washdown area to this new, proven solution. In addition to saving money on unplanned downtime and failures, the reliable new fittings help ensure consistent operations, allowing the facility to carry on the company’s mission of bringing quality and value for end users.
Following the walk-through and the introduction of ABB’s food and beverage-grade products, we have reduced turnover in our vendor managed inventory because the stainless steel fittings and washdown Liquidtight solutions have held up well in our tough conditions.Storeroom and MRO Purchasing Manager at the facility
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