Optimising an industrial production line does not depend solely on large primary machines such as kilns, presses or packaging lines. In practice, it is the auxiliary systems that ensure the process runs continuously, stably and safely.
According to continuous improvement studies in industrial environments, up to 60% of unplanned stoppages are related to internal transport issues, product accumulation or poor flow management between processes. In this context, solutions such as screens, conveyors, automatic distributors, accumulation tables, conveyor covers or elevators become key elements in maintaining productivity and final product quality.
In sectors such as the food industry, structural ceramics or bulk material handling, where volumes are high and margins are tight, a well-designed production line can make a difference of up to 20–30% in operational efficiency.
Industrial screens: controlling material from the very beginning
Rotary and vibrating screens play an essential role in material preparation and conditioning from the earliest stages of the process. Correctly separating sizes, removing impurities or classifying products before transport or further processing prevents problems that would otherwise propagate throughout the entire line.
In the structural ceramics industry, a properly sized screen ensures homogeneous particle size distribution of clay or aggregates, reducing defects during pressing, extrusion or firing. This can result in a reduction of rejects of up to 25% and greater process stability.
In the food sector, screening guarantees product uniformity, improves perceived quality and protects downstream equipment from foreign bodies.
In addition, effective initial classification reduces mechanical wear on conveyors, mills or dosing systems, contributing to lower energy consumption and reduced maintenance requirements in the medium term.
Conveyors: the backbone of the process
Industrial conveyors—whether belt, hinge, rubber, chain, roller or swan-neck elevators—form the backbone of the entire production line. They connect each stage of the process and ensure a continuous and controlled product flow.
A well-designed conveying system allows:
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Reduction of manual handling by up to 40%, lowering occupational risks.
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Minimisation of breakage and product losses, especially for fragile or high-value items.
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Improved operator safety by eliminating repetitive tasks and forced movements.
In modern production lines, internal transport can represent up to 50% of total process time, meaning that any improvement at this stage has a direct impact on overall productivity. Solutions such as swan-neck elevators make it possible to overcome significant height differences with a small footprint, keeping the product stable, without slipping or losses, and optimising available space.
Automatic distributors: balance and constant rhythm
Automatic distributors (1 to 2, 2 to 3 or 4 to 2) are essential in lines with multiple lanes or workstations. Their function is to distribute, merge or balance product flow intelligently, preventing accumulation and imbalances between processes.
Thanks to the use of servo motors, presence sensors and counting systems, these units can operate at speeds exceeding 30,000 packages per hour while maintaining precise and consistent distribution. This is particularly critical in packaging, labelling or packing lines, where poor synchronisation can create bottlenecks or chain stoppages.
The implementation of automatic distributors can improve overall line performance by 10 to 15%, especially in high-speed processes where maintaining a constant rhythm is essential.
Accumulation tables and buffers: stability in the face of the unexpected
Rotary accumulation tables and buffers act as shock absorbers within the production line. Although they are simple and robust solutions, their operational impact is significant: they absorb micro-stoppages, facilitate operator intervention and keep products organised and accessible.
In practice, these systems help decouple processes operating at different speeds, preventing a downstream stoppage from affecting the entire line. In real industrial environments, their use can reduce upstream stoppages by up to 20%, particularly during visual inspection, counting, case packing or format changeover stages.
They also help keep products off the floor, improving hygiene, order and workplace ergonomics—especially important in regulated industries.
Conveyor covers: safety and hygiene as a standard
Conveyor covers or enclosures fulfil a crucial dual function: protecting the product from external contamination and protecting operators from moving machine components.
In sectors such as the food industry, these systems are essential to comply with standards such as IFS, BRC, ISO 22000 or HACCP, reducing the risk of cross-contamination from dust, particles or accidental contact.
From an operational perspective, covers also limit dirt accumulation on belts and structures, resulting in shorter cleaning times and reduced maintenance.
In many facilities, installing conveyor covers can lead to savings of up to 30% in routine cleaning tasks, while also improving safety and overall plant organisation.
Real efficiency through well-integrated solutions
At IFAMAC, we are committed to solutions that adapt to each real process, understanding that an efficient production line is one in which everything flows smoothly, from raw material input to the final product.
Screens, conveyors, distributors, accumulators or protection systems are not secondary elements: they are what allow primary machinery to operate under optimal conditions. Because transforming a production line does not always mean making it bigger, but making it smarter, safer and more efficient by optimising every detail of the process.