Precision Manufacturing: Why it’s the Backbone of Food Processing

High-quality precision rolls drive performance, efficiency, and consistent product quality across the food processing industry. If you are struggling with lost production time, money spent on unused products, and unwanted downtime, we have the custom solution for you.

If you’re looking to incorporate roll-to-roll manufacturing into your food production, or are keen to learn more about the benefits of custom roll machinery, we’ve got the information for you.

What is Roll-to-Roll Manufacturing?

Roll-to-roll manufacturing continuously transfers flexible materials, such as food films or foils, from one roll to another, processing them into finished products. It plays a critical role in achieving consistent, high-volume food production. Whether producing cereal bars, snacks, or packaging films, precision-engineered processing rolls are essential for efficiency, product quality, and uptime.

This efficient, continuous production method allows for high-volume and cost-effective creation of products. But how does it work in the food processing sector?

How Does Roll-to-Roll Manufacturing Work for Food Processing?

Roll-to-roll manufacturing can be used across a variety of food processing applications, such as cereal bars, snacks, and much more. Over the last 30 years, we have served trusted household names such as Kellogg’s, General Mills, FritoLay, TreeHouse Private Brands, and Post Consumer Brands.

But how exactly does the process work?

Step 1: The roll-to-roll machinery continuously unwinds the flexible substrate, such as film or foil, from an input roll.

Step 2: Passing the substrate through a series of rollers and stations that coat, laminate, print, or press the food-grade materials onto it.

Step 3: Winding the finished product onto an output roll, creating a continuous, high-speed, automated production for items such as snack wrappers, edible films, or even processed sheets.

The Benefits of Roll-to-Roll Manufacturing

Efficiency, speed, reliability, and downtime are all challenges for engineers and maintenance. Roll-to-roll manufacturing can support alleviating these challenging process and production line issues. Adding custom roll manufacturing solutions to your pre-existing production line can eliminate downtime and boost production output.

We’ve listed the top benefits of roll-to-roll manufacturing below:

Faster, More Efficient Production

Due to its continuous processing, food products can pass through higher volumes in less time. This reduction in cycle time significantly increases product output compared to previous methods.

At F.N. Smith, we can provide numerous features that help maximize processing times, including no-bolt seals, grooving, and expanded grinding capacity. Incorporating these features with the latest technologies ensures a longer shelf life, ultimately resulting in less maintenance, chipping, and regrinding.

Consistent, Reliable Output

Roll-to-roll manufacturing often features real-time monitoring and automation, ensuring complete control over food materials. Specifically for the food manufacturing industry, roll-to-roll machinery creates uniform products that prevent large batch defects and promote customer satisfaction.

Minimized Downtime, Maximized Output

Roll-to-roll manufacturing boosts production efficiency by enabling high-throughput, continuous processing that reduces manual handling, lowers operational costs, and enhances overall product quality through consistent, uniform fabrication.

How Custom Roll-to-Roll Manufacturing Solves Food Processing Challenges

Custom roll-to-roll machinery can be easily integrated into pre-existing production lines. We design and build every aspect of custom machinery to integrate seamlessly into your existing product line, processes, and production goals.

Enhanced Food & Hygiene

Reducing manual handling of ingredients and food products significantly minimizes the risk of human error and cross-contamination, which are crucial for food manufacturing.

F.N. Smith designs custom roll-to-roll machinery with features that meet industry regulations and enable a safer and cleaner environment:

• High-Wear Tool Steel Construction
• Helical Water Jacket Design
• Smooth Roll Option with Crowning
• Engineered for Rework, Cleaning & Refurbishment

Seamless Integration & Ease of Use

Custom solutions are unlike standard machinery; our custom roll-to-roll solutions can be tailored from concept to installation, personalized to clients’ specific needs. This customization ensures smooth integration into the pre-existing production line and provides ease of use for all engineers and mechanics.

Custom roll-to-roll machinery from F.N. Smith can include integrated, ease-of-use features such as:

• Concept to installation design
• Bolt-on secondary designs
• HMI-controlled functions

Improved Traceability

Each custom solution incorporates automation software that processes real-time production data, ensuring food production quality assurance and meeting compliance with regulations.

Custom roll-to-roll machinery from F.N. Smith can include automated features such as:

• Centralized HMI systems
• Integrated process control

Available Features Across Custom Roll-to-Roll Manufacturing

Across all F.N. Smith custom roll-to-roll solutions, we can provide beneficial features such as:

• Four start helical water jackets
• No-bolt seals
• Emerging material technologies for longer roll shelf life: less regrind needed, less chipping, less cracking, less maintenance
• Less regrind needed
• Grooving
• Expanded grinding capacity
• Parabolic crowning 70° cosine crown
• Ceramic seal diameters

F.N. Smith Solutions – We Get The F.N. Job Done

With proven reliability and over three decades of experience, F.N. Smith has the expertise to help you achieve greater consistency and performance in food manufacturing. Our roll production experience supports:

• Increased roll life
• Reduced roll failures due to cracked shells and shafts
• Reduced production downtime
• The following solutions can support you with efficient and reliable food processing:

Flaking Roll Assembly

Our Flaking Roll Assembly is a heavy-duty component used in industrial processing equipment, specifically in flaking mills. The machinery aims to press granular materials, such as oilseeds, grains, or cereals, into flakes of a uniform thickness, preparing them for further processing, such as oil extraction or breakfast foods.

Hex Cutter Assembly

Our Hex Cutter Assembly is primarily used in the baking goods sector. The machinery features rotary cutting tools that support the rapid production of uniform, hexagonal-shaped products.

Shredding Roll Assembly

F.N. Smith’s Shredding & Sheeting Rolls feature high-wear tool steels that support the manufacturing of the roll body, increasing life between regrinds.

Your Problems End Where Our Solutions Start

Are you ready to solve your production line issues? Increased uptime, enhanced hygiene and safety, and optimal efficiency can be brought to your production with our variety of roll-to-roll manufacturing machinery. To learn more, you can contact our expert team to enhance your food production.