Worksite Improvement Case Studies

The Food and Beverage Workplace

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.

Rust problems in a hard steel wire in a spring hose

A spring hose constructed with a steel wire for strength was used for a beverage. The steel wire had begun to rust at the end of the hose where the fitting was fastened, so a braided hose with a thread was used instead of a steel wire to ensure the operation was sanitary. However, the vacuum pressure caused the hose to collapse and lose suction. The fluid flowed backwards, causing the production line to be stopped.

The food grade Olefin hose was too stiff to fill a jam into the bottle

A customer replaced a machine hose for filling jam in a sweet roll treat to comply with the Food Sanitation Act, switching from a general PVC to an olefin hose. The hose had a nozzle at the end subject to a lot of vigorous movement, but the olefin hose was too stiff to perform well.

Viscous meat flowing through a hose causes unstable flow volume, resulting in a hose rupture.

A customer had a silicone spring hose made overseas connected to a meat processing machine. When ground meat and other viscous meat ingredients were passed through, the flow volume was unsteady and a rupture resulted. They tried switching to a domestic high-pressure plastic hose, but it was stiff and difficult to use. Additionally, it was neither transparent nor made for food use.

The previous another silicone hose was bursted because of different reinforcement yarn weaving

In a plant producing yeast and other cultures, the cleaning method included an instantaneous rise in temperature and pressure. They used a typical silicone braided hose, but the thread would come out near the coupling, causing the hose to burst.

Fluid leakage in a high-temperature (80℃) vacuum environment.

On a line producing small lots of curry roux (sauce), a customer had a hose that had a vacuum, and they found roux leaking from a metal fitting during conveyance. The hose was able to handle temperatures up to 60℃, but the place with the leak was 80℃, so they began looking for a better hose. On top of that, their plant had instituted a policy to eliminate the use of PVC, so they needed to find a hose that met that requirement as well.