It is not at all uncommon for frozen pizza manufacturers to have issues with their commercial kitchen equipment. After all, this equipment is used in high-speed pizza production, which is naturally going to result in a significant amount of wear and tear. However, it is important to address pizza line efficiency and quality issues early on before they lead to time-consuming and costly downtime.
Even a relatively short downtime can be devastating for efficiency and your bottom line.
In this article, we will discuss common commercial kitchen equipment issues that can lead to downtime. We will also explore preventative maintenance, how to improve pizza line efficiency, and when you should consider upgrading your manufacturing equipment.
Pizza Belt Inefficiency
A pizza belt is one of the most important pieces of equipment you will use in your frozen pizza manufacturing company. However, it is also one of the components that is most prone to issues, which can lead to costly downtime.
Your belt and conveyor systems are under a great deal of strain during high-speed production, which can often lead to components wearing down. Not only does this increase the risk of your conveyor systems breaking down entirely, but it also reduces their efficiency. Some signs of this include slower production speeds and frequent quality errors.
Quality Errors
Speaking of quality issues in frozen pizza manufacturing, this is something that could indicate an issue with your equipment. When you are troubleshooting pizza equipment, you need to identify what is causing the quality issues.
Are there quality issues with how your conveyor system is working, or is the issue with one of your topping applicators or circle placers?
Once you have identified where the quality error is occurring, you can examine the equipment to determine the cause. In many instances, this will come down to a lack of maintenance, dirty components, or worn-down components.
Cross-Contamination
Cross-contamination is a serious problem with commercial kitchen equipment, especially when you are mass-producing frozen pizzas. This creates quality problems with your products as well as safety issues for consumers.
If left unaddressed, cross-contamination can result in downtime and can lead to more serious breakdowns. Some common causes of cross-contamination are dirty equipment components and a lack of regular maintenance and sanitization.
Misaligned Toppings
Another very common manufacturing issue you have probably experienced while troubleshooting pizza equipment errors is misaligned toppings. This often occurs when there is something off with how the crust is placed on the conveyor system or how the toppings are added to the crust.
Misaligned toppings can result in wasted ingredients and downtime, especially if they go unnoticed for some time.
Improving Pizza Line Efficiency With Preventative Maintenance
Now that you know how to go about troubleshooting pizza equipment problems, how do you prevent these problems from occurring in the first place? The number one secret all frozen pizza manufacturers need to remember is preventative maintenance. By practicing preventative maintenance, you can ensure your equipment is always running optimally and has the least risk of breaking down.
Here are some common preventative maintenance standards you should have in place to ensure your equipment lasts as long as possible:
- Daily Cleaning: Any type of food manufacturing company needs to have established daily cleaning routines that employees follow. Daily cleaning ensures equipment is hygienic and doesn’t create cross-contamination risks. Additionally, cleaning on a regular basis ensures machinery is not jammed with food debris.
- Sanitization: Besides having equipment cleaned on a daily basis, you also need to have your equipment sanitized. This may need to be done weekly or monthly, depending on the equipment, and you may need to outsource it to a cleaning company. Sanitization usually involves a much deeper cleaning with special equipment and products.
- Regular Maintenance: Having equipment maintenance on a regular basis also helps to catch any issues before they become more significant. At Quantum, one of the services we provide is preventative maintenance and equipment servicing so that your equipment stays in tip-top condition for as long as possible.
- Early Repairs: Regular maintenance allows you to spot potential issues before they escalate. However, you do not want to delay repairing your equipment as this often results in downtime and more significant repairs. It is always best to address issues as early on as possible to avoid a more time-consuming and expensive repair later on.
Troubleshooting Pizza Equipment Issues: When It’s Time to Upgrade
No matter how well you take care of your commercial kitchen equipment, there will come a day when you need to upgrade. This is inevitable, especially since frozen pizza manufacturing is very strenuous and will wear down equipment over time. On average, manufacturing equipment only lasts between 10 and 20 years, and you may need to upgrade before then.
Here are some signs that it may be time to invest in upgrading your equipment:
- Limited Flexibility: Even if your equipment is still running well, you may need to upgrade if it no longer fits your needs. It may not provide flexibility regarding different ingredients or products, or it may not be configurable to meet slow and busy seasons.
- Frequent Breakdowns: As equipment gets older, you may find that you have to fix it more frequently to prevent significant breakdowns and downtime. It may get to the point where it is more affordable to simply invest in new equipment rather than to maintain old equipment.
- Outdated System: Manufacturing technology has advanced significantly in the last few years, which can make your equipment outdated. For instance, at Quantum, we provide a variety of automated equipment options, allowing you to rely on automation instead of manual labor.
Improve Efficiency and Reduce Downtime With Quantum
Does your frozen pizza manufacturing company need to produce at least 20 pizzas per minute? At Quantum, we design durable and reliable equipment for high-speed production that improves quality, efficiency, and reproducibility. Our equipment is built to last and offers a variety of customizable settings, allowing it to grow with your company. Contact our team today to learn more about the commercial kitchen equipment we provide for frozen pizza manufacturers.