The maths is simple: an unplanned shutdown of a meat processing line costs between CHF 5,000 and 50,000 per hour. A planned maintenance visit on the same line costs a fraction of that — and ideally prevents exactly that failure.
Yet many operations in the Swiss food industry still rely on the strategy of “we’ll fix it when it breaks”. This is understandable — production schedules are tight, downtime is hard to plan, and maintenance costs appear avoidable. But in the long run, this strategy is the most expensive.
Three Maintenance Strategies Compared
Reactive Maintenance (Run-to-Failure)
The machine runs until it fails, then it’s repaired. This strategy is only suitable for non-critical components whose failure doesn’t cause a production stop.
Pros: No planning needed, low short-term costs. Cons: Unplanned shutdowns, collateral damage, emergency surcharges, spoiled goods.
Preventive Maintenance
Maintenance at fixed intervals — time-based or by operating hours. The most common and proven strategy for the food industry.
Pros: Predictable costs, reduced failures, longer equipment lifespan. Cons: Some parts replaced too early, maintenance even without actual need.
Condition-Based Maintenance
Sensors monitor equipment condition in real time. Maintenance occurs only when readings indicate wear. Requires investment in IoT/sensor technology.
Pros: Optimal component utilisation, minimal downtime. Cons: High initial investment, data analysis required.
What Does Preventive Maintenance Include?
A professional maintenance plan for food industry production lines covers at minimum:
Mechanical Inspections
- Condition of bearings, guides, and drive elements
- Chain and belt tension and wear
- Conveyor belts and transport roller wear
- Seals and O-rings on washing and processing systems
- Corrosion checks on stainless steel components
Electrical Inspections
- Motor and cable insulation resistance
- Contactor and relay condition
- Variable frequency drives: firmware, parameters, fans
- Safety circuits (emergency stops, light curtains, door switches)
- Earthing measurements
Automation
- PLC backup (not just once — regularly!)
- HMI/SCADA parameter backup
- Sensor calibration (temperature, pressure, flow)
- Network component checks (switches, OPC UA servers)
Typical Maintenance Intervals
| Component | Interval | Critical? |
|---|---|---|
| Conveyor belt tension | Monthly | Medium |
| Chain lubrication/tension | Every 2 weeks | High |
| Drive unit bearings | Quarterly | High |
| Washing system seals | Bi-annually | High |
| Electrical panel inspection | Annually | Medium |
| PLC backup | Quarterly | Critical |
| VFD service | Annually | Medium |
| Safety circuit testing | Bi-annually | Critical |
ROI: What Does Preventive Maintenance Save?
For a mid-sized food company with one main production line, preventive maintenance typically pays for itself:
- Maintenance contract: CHF 12,000–24,000 per year (4 visits of 1–2 days)
- Avoided failures: At least 1–2 unplanned shutdowns of 4–8 hours each
- Saved costs: CHF 20,000–100,000+ per year
- Additionally: Longer equipment lifespan (+20–30%), lower energy consumption
How to Get Started
- Assessment: Which systems are critical? Where have unplanned failures occurred in the past 2 years?
- Prioritisation: Don’t do everything at once — start with revenue-critical lines.
- Choose a partner: An external maintenance partner with industry experience is often more efficient than an internal team.
- Create a plan: Based on manufacturer specifications and your operating conditions.
- Document: Every maintenance visit must be logged — for internal tracking and audits.
Conclusion
Preventive maintenance isn’t an expense — it’s an investment in the operational reliability of your production. In the food industry, where unplanned failures cost not just money but also product and reputation, it’s indispensable.
VLD Service offers tailored maintenance contracts for the Swiss food industry — including 24/7 emergency standby. Contact us for a quote.
