Getting the Most from What You’ve Got: Maximizing the Efficiency of Your Existing Food Processing Equipment

Although new federal laws allowing for Bonus Depreciation (i.e., additional first-year depreciation) of equipment constructed after January 19, 2025 make CapEx equipment purchases more accessible than ever, smart manufacturers continually look to improve the productivity, efficiency and reliability of the equipment they already own. For cooking and mixing vessels, several actions can help maximize equipment performance and longevity.

Upgrade in Stages: Start with the Agitator

A common bottleneck in food processing equipment isn’t always the vessel itself—it’s often the agitator. If your current kettle has an agitator that’s old, worn out or not finely tuned to your present-day production needs, you don’t necessarily need to replace the entire unit. You may be able to start by replacing or modifying just the agitator.

A new or upgraded agitator will benefit all aspects of your mixing operation, from product quality and batch-to-batch consistency to improved speed and throughput. It can help you accommodate a wider range of viscosities, enhance energy-efficiency, and can be customized to suit specific processes and products. By improving your agitator now, you’ll enjoy immediate performance gains. And when the time does come to replace the kettle body, your new vessel can be built to work seamlessly with the upgraded agitator.

Field Service: A Path to Better Performance

You may be surprised how much performance you can unlock with a comprehensive equipment evaluation by an experienced field service technician. These professionals can help you spot problems and opportunities with your vessels that can keep your current equipment running smoothly and maximize productivity.

A thorough service check typically includes:

• Inspecting and repairing the drive unit and agitator shaft
• Evaluating and replacing worn bearings, bushings, and seals
• Checking for signs of fatigue or stress in high-wear areas

Often, relatively minor maintenance or component replacements can have a major impact on your uptime and processing efficiency, as it will help you avoid unexpected and costly breakdowns.

Build a Strategic Spare Parts Inventory

Another critical step in keeping your operation running smoothly is having the right spare parts on hand. When something breaks, waiting for a component to arrive can lead to lost production; and during a time of global trade uncertainty, the potential for delays grows.

That’s why it makes sense to stock key components that are most prone to wear. Think of it as insurance for your productivity. Common wear parts — such as scraper blades and pins, O-ring seals, drive shaft bearings, seals and ball valve seal kits — should be readily available so your maintenance team can respond quickly to any issues. Components that must be custom-fabricated for your specific vessel—like internal drive shafts—carry an even greater threat of costly downtime and are therefore critical to have spares in inventory.

No Equipment Drawings? No Problem.

Many facilities work with vessels that have been in use for years—sometimes decades—and in some cases, the original design drawings or equipment documentation have long since disappeared (Note: Lee Industries keeps drawings dating back to the 1940s). That doesn’t have to be a barrier to optimization.

A skilled field service technician can come on-site to assess your equipment, take the necessary measurements, and help you identify specs for parts, repairs or upgrades. With that information in hand, you can make informed decisions about refurbishments or retrofits.

Collaborate with an Applications Engineer

Lastly, don’t underestimate the value of talking to an experienced applications engineer. These professionals live and breathe process optimization, and they know how to get creative with limited resources. Whether you’re looking to expand production, adapt to a new product or recipe or improve yield, an applications engineer can help you brainstorm solutions that make the most of what you already have.

An applications engineer may be able to recommend a retrofit, help add efficiency to your line to reduce processing time or identify ways to improve throughput. The goal is to boost performance as efficiently as possible

You May Be Surprised

Don’t settle for reduced productivity or increased risk of downtime. By taking a strategic approach—upgrading components, investing in preventative maintenance, stocking critical spare parts and seeking expert guidance—you can significantly extend the life and efficiency of your current food processing equipment.

With a little effort and the right partners, your existing equipment will likely surprise you with just how much it can still deliver.

Our applications engineers would be happy to discuss ways to make the most of your existing operation. Just contact us to get started.