DFS Drastically Reduces Downtime with Intralox Service and DirectDrive System

Customer Objectives

Diversified Foods and Seasonings (DFS)—a custom food manufacturer for multi-unit restaurants—needed a more efficient and reliable solution for freezing their 2.5- and 5-lb (1.13- and 2.27-kg) plastic bags of ready-to-eat, kettle-cooked sides. DFS’s two metal friction-driven spiral systems had presented many issues over the years. Belt flips, backups, punctured bags, and product jams caused costly product loss, frequent expensive maintenance, and unscheduled downtime. Then, in 2019, the catastrophic failure of one spiral freezer destroyed 50% of the plant’s production output. Long lead times for drum and metal belt replacements would’ve further hindered production for months.

Intralox Execution

Having had positive past experiences with Intralox, DFS contacted us for help. Our reliable belt stock and OEM relationships allowed us to quickly provide all materials and labor needed to replace the failed spiral with a DirectDrive System spiral with Series 2800 belting. DFS’s freezer was back online and producing in half the time it would’ve taken to repair the metal friction-driven spiral.

Intralox’s DirectDrive spiral didn’t just lessen the plant’s downtime; it also drove significant improvements in DFS’s ongoing maintenance and production. In 2021, DFS replaced their second metal friction-driven spiral with another DirectDrive spiral and enlisted us to replace and optimize both spirals’ control systems.

Results

Since initial installation, the Intralox DirectDrive spirals have performed flawlessly. DFS’s maintenance requirements, downtime, and product loss have all dropped significantly. Further, the spirals’ gentle product handling and reliable, efficient freezing allow DFS to continuously run product through their system for up to 48 hours without issue. The DirectDrive spirals transformed what was previously a problem area that required constant maintenance into a seamless, reliable, and largely “hands-off” ready-meal conditioning operation. DFS is now looking for more opportunities to continue optimizing production, handling, and freezing with Intralox.