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Contexte

\n

Fondée il y a plus de 150 ans à Castel di Sangro, en Italie, Orlando Baking Company exerce ses activités sur plusieurs sites à Cleveland, Ohio, depuis plus d'un siècle. Orlando Baking fabrique des pains européens et des produits de boulangerie sur commande, notamment des miches, des petits pains et des pains surgelés, destinés aux marchés et aux épiceries de l'Ohio et des États voisins.

\n

Défi

\n

L'un des produits surgelés les plus populaires d'Orlando Baking, le « Texas toast », est élaboré à partir d'épaisses tranches de pain blanc grillé et beurré. La société surgèle ce produit grâce à un surgélateur en spirale à faible charge. Le pain grillé produisait de la matière grasse qui s'immisçait lors de la friction entre le tambour et le tapis de la spirale ; cela entraînait de nombreux problèmes sur le tapis en spirale, notamment des dérapages, des saccades et des « retournements ». 

\n

L'orientation du produit constituait un autre défi dans la mesure où les tranches de pain se retrouvaient souvent de travers ou mal alignées au fil de leur déplacement sur le tapis en spirale. Deux opérateurs étaient mobilisés pour réaligner les tranches de pain près de la zone de décharge du tapis en spirale. Cependant, le risque de pertes de produits était une source d'inquiétude constante.

\n

Solution

\n

Lasse de batailler contre ces problèmes de spirales, la société Orlando Baking s'est adressée à Intralox afin de trouver une solution à ses défis de surgélation. Le système DirectDrive, élément du programme d'optimisation spirale d'Intralox, a répondu à ses attentes. 

\n

Le système DirectDrive élimine la surmultiplication en utilisant l'entraînement positif pour emboîter les bords du tapis directement sur le tambour, même en cas de traces de beurre ou de matière grasse. Ainsi, le tapis en spirale avance sans aucun dérapage et sans friction entre le bord du tapis et le tambour. En installant le système DirectDrive, les usines peuvent améliorer l'orientation de leurs produits et la capacité de charge tout en réduisant les coûts de nettoyage et en simplifiant les contrôles du système de spirale. Le programme d'optimisation spirale d'Intralox améliore les opérations grâce à un service clientèle, une assistance technique et un savoir-faire inégalés.

\n

Résultats

\n

Depuis l'installation du système DirectDrive en avril 2012, Orlando Baking ne rencontre plus de problèmes liés aux applications en spirale et bénéficie en prime d'avantages opérationnels considérables. La société a pu se passer du travail des deux opérateurs près de la zone de décharge du tapis en spirale et réduire la tension du tapis de manière significative. L'usine n'a déploré aucun temps d'arrêt depuis l'installation du système. 

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Par ailleurs, Orlando Baking s'est montrée très satisfaite du service et de l'assistance reçus dans le cadre du programme d'optimisation spirale d'Intralox. « Le service fourni par Intralox est exceptionnel », déclare John Orlando, vice-président des opérations de la société. La société envisage d'installer le système DirectDrive sur un autre surgélateur en spirale de leur usine de Cleveland.

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