Traditional water-cooled presses can create hygiene risks for food and beverage manufacturers. Flexco introduces its latest technology to make splicing safer, faster and easier.
When it comes to food and beverage manufacturing, conveyor belts are essential for automating material handling and improving processing stages. With their versatility, they are used for transporting bulk food products gently and with consistent movement. However, what happens when part of the belt is damaged or contaminated?
Many food manufacturers join the ends of a belt by creating a continuous loop or repairing a damaged section with an endless splice press. A properly spliced belt ensures smooth material flow, reducing the risk of misalignment, which can shut down operations.
Lightweight belting made from materials such as PVC and polyurethane plays a crucial role in product movement. These belts are highly valued in the food and beverage industry and require high-quality splices to ensure products move efficiently and safely through production lines.
Achieving a quality splice requires precise control over time, temperature, and pressure during the splicing process. For manufacturers in this sector, the splice must not only deliver excellent results but also meet stringent hygiene and safety standards.
Disadvantages of water-cooled presses
For more than a decade, Michelle Graves has led as product manager of Endless Splicing Novitool Products at Flexco, overseeing the development of splicing solutions to meet the changing needs of material handling industries like food and beverage.
She said that traditional splicing equipment often posed certain challenges. Water-cooled presses, for example, are heavy to manoeuvre and require multiple components such as external control boxes, water buckets, and hoses. Using water-cooled presses is not only cumbersome but also presents hygiene risks, as water systems can harbour bacteria.
“Using a splice press with air-cooling technology integrated into the machine means no outside tanks or water sources are needed, drastically reducing set-up and tear-down time, as well as overall splice time and incident costs,” Graves explains.
From a sanitation perspective, this helps to eliminate cross-contamination concerns that may be a result of external water sources coming into contact with production equipment.
In addition, these older presses can take up to an hour to complete a splice from heating to cooling, slowing down production schedules. Some equipment is also supplied without adequate after-sales support, leaving operators without proper training, guidance on recipe settings, or reliable servicing.
Novitool® Aero® splice press with IntelliSplice™ technology
Flexco has recently announced the release of the latest edition of their Novitool Aero splice press equipped with IntelliSplice technology.
It is an all-in-one solution that is more intuitive than ever for operators of all levels, from splicing specialists to first-time users.
A splice can be completed, from heat-up to cool-down, in eight to 12 minutes, reducing downtime and improving efficiency. Independent heating control allows operators to set different temperatures for the top and bottom of the press, enabling precise splicing.
It also includes top and bottom forced air-cooling systems, bringing the splice to a safe temperature before it is put back into service. With a 150 mm heat zone, the prepared belt fingers can bond evenly and securely.
The Aero splice press eliminates water-based cooling systems and uses clean-air cooling to ensure a sanitary process. The rapid splice cycle minimises the time belts are out of service, supporting continuous production and reducing downtime.
Touchscreen with recipes
Compared to earlier models, the press offers a more intuitive interface with a touchscreen display. Graves noted that the touchscreen is complemented by a d-pad thumb toggle, giving operators additional navigation options.
Recipe management is another feature. Operators can store specific recipes directly on the press, ensuring consistent splice quality every time. The four-inch display allows users to enter, save, and load recipes.
This is important in facilities with multiple operators, as everyone can work from the same parameters, reducing errors and maintaining quality. Built-in diagnostics alert operators if a setup step has been missed, preventing faulty splices and further downtime. A help section includes manuals, videos, and troubleshooting resources to support users in real time.
“As we’re looking to add technology to the Aero, we wanted to ensure we were adding value for our customers,” said Graves.
She explained that the design was shaped by customer feedback, with Flexco’s product and IT teams visiting belt fabrication shops and end-users to identify top priorities. Improved recipe management and enhanced press diagnostics emerged as the main requests, both of which are now core features.
For food and beverage manufacturers, where product integrity and operational efficiency are critical, recipe storage reduces training needs and prevents inconsistency between operators – an inconsistency that can compromise product quality. Coupled with precise temperature control and a faster splice cycle, Graves emphasises how streamlined conveyor operations can be made “reliable, productive, and safe as possible”.
Splice anywhere and everywhere
The portability of the Novitool Aero splice press is another feature.
“Every Aero comes with a transport case which is valuable in moving it from place to place,” said Graves.
The four wheels on the case allow the press to be rolled directly to the conveyor location. This saves time and effort for operators, especially in large manufacturing facilities where equipment often needs to be relocated.
Training with a bigger picture
According to Graves, Flexco’s commitment to customer support goes beyond supplying equipment. The company provides specialised operator training, helping users understand how to use the press effectively.
Flexco offers custom training at their brand new training facilities in Sydney and Perth, or they can provide onsite training for added convenience at the customer’s facility.
These on-site sessions also give Flexco the ability to assess their conveyor systems, identify potential improvements, and suggest complementary products from Flexco’s Light-Duty Belt Conveyor Product range , such as food grade cleaners and transfer plates.
“My colleague and I visited several distributor belt fabrication shops and end users to learn about their unique belt conveyor challenges and how we can minimise downtime and improve throughput,” she said.
This approach helps customers maximise the performance and reliability of their entire conveyor operation, not just the splicing process.
“Flexco’s vision is to be the most valued partner for conveyor solutions,” Graves added.
Flexco’s core values are People First, Better Together, Customer Centred, Forward Thinking, and Committed to Excellence. Graves stressed that these values are essential in defining the company’s culture, behaviours, and mindset as a solutions provider for the food and beverage industry.
By working closely with customers, the company can identify industry-specific challenges and develop tailored solutions. This customer-focused approach builds trust and long-term relationships, ensuring that the equipment provided continues to meet evolving needs.
With a goal to help manufacturers achieve better conveyor operations, the splice press combines advanced technology, intuitive design, and customer engagement to set the standard for splicing in the food and beverage sector.
As manufacturing demands continue to evolve, Flexco remains committed to adapting its solutions to meet those needs.
“The Novitool product range offers the best-in-class endless splicing systems,” said Graves. “Flexco promises to be a partner you can trust to deliver expertise, superior service, and quality solutions that make your conveyor operation reliable.”