90% Less Spillage. 57% Less Cleaning Time. ROI in 1.5 Years.
How a leading extruded snack manufacturer in the Philippines transformed its conveyor line — and recovered $12,500 in annual material savings.
Product Loss and Cleaning Costs Were Compounding Daily
A leading extruded snack manufacturer in the Philippines was losing approximately $14,000 worth of product annually due to spillage on its existing conveyor line. The snacks — a coated extruded format particularly prone to breakage and spillage — were falling off poorly designed transfer points and overflowing belt edges that lacked adequate buffer capacity.
The cleaning situation was equally costly. It took 3 workers 5 hours per shift to clean the line — a significant labor commitment that also reduced available production time. Together, product loss and cleaning cost were quietly adding up to a substantial annual burden.
Cleaning: 3 workers × 5 hrs per shift
Lost production time
Cleaning: 1 worker × 2 hrs per shift
+2,300 kg/day recovered throughput
A Conveyor Designed Around the Product — Not the Other Way Around
Enabling.Win replaced the existing conveyor with a product-specific ITP design. The new system attacked spillage on multiple fronts: belt width and flight height calibrated to the product's density, synchronized side walls that move with the belt to prevent underflow spillage, and precisely engineered in-feed and discharge transfer points with sufficient overlap to eliminate fallout.
- Product-specific ITP conveyor replacing the mismatched line
- Belt width and flight height calibrated to the product's density
- Synchronized side walls that move with the belt to stop underflow spillage
- Precision in-feed and discharge transfers with overlap to eliminate fallout
- Open-frame design that eliminates inaccessible areas
- Tool-less belt/component removal plus a CIP air & water assembly for deep cleaning without full dismantling
The 1.5-year ROI is a direct result of addressing the root cause — a conveyor design that simply wasn't matched to the product. When belt geometry, transfer engineering, and cleanability are optimized together, the savings aren't marginal. They are structural and compounding.
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