Client: Industrial Pizza Manufacturer
Application: High-Output Freezer Outfeed (Radius / Curve Conveyor)
Specifications: 40-Meter Length x 990mm Width
Product Installed: Star Modular HS2400B (1.7) Tight-Radius Belting
The Challenge
The client was experiencing severe operational disruptions on a massive 40-meter-long freezer outfeed conveyor. The existing 990mm wide radius belt was consistently lifting out of its side guide tracks, bending/buckling in the centre, and completely flipping over mid-production.
Beyond the catastrophic jams and ruined product, the belt flipping over created a major Health & Safety risk on the factory floor. A heavy, wide modular belt lifting and snapping out of its tracks under high tension poses an immediate danger to nearby operators from flying plastic components, moving parts, and displaced products. Every time the belt failed, it endangered staff and forced emergency maintenance in a high-risk area.
The Solution
Our team conducted a thorough application survey and diagnosed the root cause: the conveyor’s physical curve was running at the absolute tightest turning radius the original belt was capable of handling. The excessive lateral tension was forcing the centre of the belt to bow upward, overpower the retention tracks, and violently flip out.
We implemented a two-part re-engineering strategy to secure the line:
- High-Flexibility Belt Upgrade: We replaced the failing belt with our specialized Star Modular Tight-Radius Belting, specifically engineered to handle tight collapse factors and high cornering loads without tenting, buckling, or lifting.
- Lane Optimization & Guarding: Noticing that the pizzas did not require the full 990mm width of the conveyor bed, we strategically adjusted and narrowed the guide rails. This kept the product perfectly cantered while reinforcing the containment of the belt itself.
The Result
The upgrade completely transformed both the reliability and the safety of the freezer line. The new tight-radius belt tracks flawlessly through the entire 40-meter circuit with zero centre lifting, buckling, or tracking failures.
Most importantly, the major Health & Safety hazard has been completely eliminated, ensuring a fully compliant and safe working environment for the factory floor staff. The manufacturer now runs 24/7 freezer operations with total peace of mind, zero radius-related downtime, and zero safety incidents.
Talk to us about our solutions
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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