Core Principle: Combine daily cleaning, scheduled PM (Preventive Maintenance), and thorough overhauls to ensure efficiency, safety, product quality, and equipment longevity.
1. Daily Maintenance (Operators)
Clean: Thoroughly sanitize ALL food-contact surfaces (mixers, conveyors, cutters, proofer, fryer baskets/belts, cooling racks, glazers, packers) after shifts/batch changes. Remove dough, grease, icing, sugar. Use food-grade cleaners.
Inspect: Check for leaks, unusual noises/vibrations, smoke, belt wear/misalignment, loose fasteners, safety guards. Monitor fryer oil quality (temp, color, foam, smell).
Lubricate Sparingly: Apply food-grade lubricant ONLY to specified points (chains, bearings). Wipe excess.
Record: Log findings and actions.
2. Scheduled PM (Technicians/Operators)
Weekly/Bi-weekly: Deep clean removable parts. Check/adjust belt tension, tighten bolts, inspect motors/gearboxes, check air systems, verify safety devices, calibrate fryer temp controls. Relubricate.
Monthly: Inspect heating elements, bearings, chain/belt wear, electrical connections, drive alignment. Deep clean fryer interior (vats, tubes, exhaust). Clean glaze/sugar systems (pumps, nozzles).
Quarterly/Biannually: Replace high-wear parts (belts, chains, seals, filters). Check motor brushes/bearings. Change gearbox oil if needed. Control panel dusting. Calibrate key parameters.
Annually: Full system shutdown. Comprehensive inspection, cleaning, lubrication, adjustment, parts replacement. Performance & safety testing. Professional assessment.
3. Key System Focus Areas
Mixing: Clean paddles/bowls. Check shaft seals. Lubricate bearings.
Forming/Cutting: Clean molds/cutters daily. Inspect sharpness/wear.
Proofing: Clean chamber. Calibrate temp/humidity sensors. Maintain humidifiers.
Frying (CRITICAL): Skim, filter oil daily. Remove carbon buildup weekly. Inspect heating elements, sensors, pumps monthly. Use high-temp food-grade lube.
Cooling: Clean belts/tunnels. Check fans.
Glazing/Topping (CRITICAL): FULL CLEAN after EVERY USE/BATCH CHANGE. Inspect nozzles/pumps.
Conveying: Clean belts. Maintain tension. Lubricate chains/bearings. Check rollers.
Packaging: Clean contact surfaces. Verify sealer settings. Lubricate moving parts.
4. Success Factors
Detailed PM Schedule: Tasks, frequency, responsibility, tools/supplies.
Correct Supplies: Food-grade lubricants, cleaners, sanitizers.
Accurate Records: Track all maintenance, issues, parts used.
Training: Equipment operation, PM procedures, SAFETY (LOTO – Lock Out Tag Out!), food safety.
Spare Parts: Stock critical wear items.
Continuous Improvement: Analyze failures, optimize PM.
SAFETY FIRST: ALWAYS perform LOTO before ANY maintenance! Beware of hot oil, moving parts, electricity.
