Worksite Improvement Case Studies

The Food and Beverage Workplace

Frequent hose replacement with hose assemblies in use means high costs and long lead times for crimped products, requiring countermeasures

During the flavoring filling process, a food-grade silicone hose and crimping couplings were used, but the frequent suction and pressure feed in the process meant regular hose replacement; costs mounted for crimping couplings which could not be reused.

Liquid accumulation between barb fittings and hose is a concern due to dairy components in the flavorings produced

Newly introduced production of flavorings containing large amounts of dairy components requires more stringent bacterial inspections, due to the nature of the product. The hoses are currently connected with barb fittings for hose clamp fastening, but the bumps may lead to liquid accumulation, requiring countermeasures.

Raw materials adhere to the hose due to static electricity when transporting food raw materials, reducing the flow rate!

Hoses are being trialled for transporting raw materials at a marine product processing plant. However, raw materials adhere to the hoses due to static electricity, and the flow rate is significantly reduced, resulting in reduced production efficiency.

Disconnection of couplings during high-temperature cleaning and sterilization of food transport lines is a concern

For transporting raw materials at a soy sauce manufacturing plant, TOYORING-F Hose 38φ and barbed cam locks were used with hose clamp fastenings. However, during cleaning and sterilization, hot water at 80°C flows at a pressure close to the upper limit of the allowable pressure for a short time.

Leakage occurs when the hose clamp fastening is tightened!

Hoses and cam locks are used to fasten hose bands used for transporting food products at a fermented food manufacturing plant. Leakage from the couplings. A countermeasure is needed.

Removing and reattaching 200 hoses every day for cleaning is a lot of work!

TOYOSILICONE Hoses were used for conveying salad dressing and the hoses were initially cut to about 30 centimeters and fastened with clamps. But there were between 100 to 200 hoses in the plant, and they all had to be removed, washed and reattached every day. There were two problems:

(1) It took too much time
(2) The edges of the clamps were causing damage to the hoses, which had to be replaced.

Cleaning alcohol makes the hoses stiff, causing outbreaking crack on the serface and leaks

A customer was cleaning hoses with a high concentration of cleaning alcohol. Because the hoses were made of PVC, the alcohol caused the hoses to become brittle, and they cracked, causing material to leak.

I want to change hoses to meet the revised Food Sanitation Act, but oils & fats remain a problem.

On a chocolate production line, a 38-millimeter PVC braided hose was in use. To comply with Public Notice No. 267 under the Ministry of Health, Labour and Welfare’s Food Sanitation Act, a replacement was needed right away. When they looked for food-grade hoses, they found a number of candidate products from other companies, but none could handle the oils and fat in chocolate.

Machinery vibration causes sanitary beverage hoses to become displaced and make a lot of noise!

Sanitary beverage hoses were making a lot of noise due to machinery vibration and were becoming displaced. They tried inserting a hose at the connection point to absorb the vibration, but then they had problems with the heat and acetic acid used during cleaning, meaning that sanitation was also an issue.

Stainless steel pipes are difficult to lay out and the material inside is not visible.

Lacking a heat-resistant hose, a customer used a stainless steel pipe for a food equipment pump that provided a pressure feed and a vacuum. They came to us and asked if we had a heat-resistant flexible pump that would allow them to check the material inside, and we looked for a solution for them.