Eliminating Belt Stretch & Downtime for a Major Pizza Manufacturer

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Client: Industrial Pizza Manufacturer

Application: Packaging Line / Heavy Box Conveying

Product Installed: HS1000A EL Grey Modular Belting with Rubber Grip Top

The Challenge

The manufacturing facility was using traditional flat belts to transport packed boxes of pizza weighing up to 10kg. Because flat belts rely entirely on high tension and friction to move, the heavy 10kg loads caused the belts to stretch out on a regular basis.

This constant stretching led to tracking issues, belt slippage, and frequent, costly production downtime while maintenance teams constantly adjusted and re-tensioned the lines. The client needed a permanent, heavy-duty solution that could handle the weight without sacrificing reliability.

The Solution

Star Modular Belting provided a complete engineered upgrade, moving the client away from unreliable friction drives to a reliable, positive-drive modular system.

We brought the conveyors to our workshop and executed a full system modification:

Custom Engineering: Manufactured brand-new shafts specifically designed to accommodate positive-drive sprockets.
Bed Modifications: Altered the conveyor bed profile to provide the new sprockets with maximum clearance to spin freely.
Premium Belt Retrofit: Installed our heavy-duty HS1000A grey modular belting, fully equipped with a rubber grip top to ensure the 10kg boxes remained completely stable during transit.

The Result

By converting the system from a tensioned flat belt to a sprocket-driven modular belt, the root cause of the belt stretch was completely eliminated. The positive-drive design means the belt never slips or loses tracking, regardless of the load. The rubber grip top securely handles the heavy pizza boxes, providing smooth, consistent product transfer. The client has seen a dramatic reduction in maintenance hours and zero load-related downtime since the installation.

Couldn’t recommend Rob and Star Modular belting highly enough. I was in need of modular sections for a conveyor belt, all companies I contacted stated long lead times, then I found Rob, he had the exact parts I needed next day. A couple of months later, I needed a whole new modular belt, I sent Rob the dimensions and he had the belt sent in after 2 days, it fit perfectly with no issues. Absolutely phenomenal company, as a new customer I expected to be less of a priority but Rob and his team made me feel like a valued customer. I will absolutely use this company going forward for all my modular belt needs.
Thanks again Rob, and please pass on my thanks to all the guys who have worked around the clock to get me the parts I needed!

Ryan Harris

We at Fine Lady Bakeries Ltd have used Star Modular belting for many years comparing their belts with other companies we have found they last long and are very hard wearing as a bonus they are very competitive to other belt manufacturers and with a lot of stock held for us in the UK delivery is normally very quick I would recommend Star Modular Belting to any company or bakery using these types of belts.

Francis Furling, Fine Lady Bakeries

We have been continuously replacing sections of belting with one of the Intralox conveyors, spending over 4K in 2 years. Star Modular surveyed the belt and advised that it was built with a minimum manufacturing bend radius, which was over-stressing the belt, causing repeated failures. They replaced it with a tight-turning belt. Problem solved!

Paul Docherty, Asset Manager Controller, Warburtons

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Star Modular is a family-owned company with over 30 years of combined conveyor belting experience. We understand what to look for when belt problems occur and pride ourselves on delivering responsive, customer-focused service that often exceeds that of our competitors.

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