Expedited Screw Upgrade Prevents Downtime at Smithfield Foods

Introduction

Smithfield Foods is one of the largest pork producers and meat processing companies in the U.S., with well-known brands including Smithfield, Eckrich, and John Morrell. Screw conveyors are widely used throughout Smithfield facilities to transport meat byproducts for recycling. Bearing Headquarters (BHQ), a leading industrial distributor specializing in power transmission and material handling solutions, serves as a preferred supplier for many Smithfield plant locations.

KWS Upgraded Screw Construction to Significantly Increase Rigidity and Eliminate Failure

Challenge

A critical screw conveyor component unexpectedly failed during production, creating an urgent need for a replacement screw to keep operations running. BHQ immediately contacted KWS for an expedited solution that would not only replace the failed screw but also improve long-term reliability in the demanding environment.

The failed screw was non-standard with schedule 80 center pipe and unique diameter. The screw failed premature due to poor design and construction. Standard manufacturing lead times would have resulted in extended downtime and costly production losses for Smithfield Foods.

KWS Advantage

KWS upgraded the center pipe from Schedule 80 to XXH pipe to significantly increase rigidity and eliminate failure. The upgraded design provided Smithfield with a more robust and reliable long-term solution. KWS coordinated production and shipment on an accelerated schedule to ensure the replacement screw was delivered within two days of the original screw failure.