16 Conveyors Reduced to 7 — and $65,000 Saved
How a leading split faba bean processor in Indonesia achieved significant CAPEX and OPEX savings through hygienic conveyor redesign.
A Dense Layout With Too Many Transfer Points
A leading split faba bean processor in Indonesia was operating a production line with 16 conveyors — a layout that had grown organically over time and carried the inefficiencies that come with it. Each additional conveyor represented another potential spillage point, another cleaning burden, and another maintenance cost.
Split faba beans present specific handling challenges: they are fragile and prone to breakage at poorly designed transfer points, and their dust and fine particles accumulate quickly in conveyor systems not designed for easy cleaning. The existing layout made both problems worse.
Heavy cleaning & maintenance burden
Breakage and dust accumulation
Lower cleaning & maintenance cost
Gentle handling, fewer failure points
Engineered for Fewer Touchpoints and Easier Cleaning
Enabling.Win surveyed the full production line and redesigned the conveyor layout from the ground up. By eliminating non-value-adding conveyors and redesigning transfer points to minimize product drop height and spillage, the team reduced the line from 16 conveyors to just 7.
- Full line survey and ground-up layout redesign
- Non-value-adding conveyors eliminated — 16 reduced to 7 (56% reduction)
- Transfer points redesigned to minimize product drop height and spillage
- ITP design with tool-less belt removal and open-frame construction for full CIP access
- Synchronized side walls to prevent underflow spillage
- Intralox ThermoDrive belting for gentle product handling
The $15,000 annual OPEX saving reflects reduced cleaning time, lower maintenance frequency, and fewer breakdown events — the compounding costs most manufacturers don't fully account for when specifying conveyor systems. By designing for cleanability and reliability from the outset, the new layout pays for itself faster and keeps delivering savings year on year.
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