In any plant, the production line is the heart of operational performance. Every buildup of residue, deposits, or contamination can slow operations, increase incident risks, and reduce equipment lifespan. Professional, regular maintenance is therefore not just “cleaning”—it is a direct lever for productivity, safety, and cost reduction.
This article outlines the essential best practices to keep your production lines operating at peak capacity while meeting the safety, hygiene, and compliance standards specific to your industry.
Why Production Line Cleaning Is Essential
Optimize Operational Performance
Raw material residues, dust, oils, and micro-debris naturally accumulate over production cycles. Without rigorous maintenance, they lead to:
- mechanical slowdowns;
- decreased conveyor speed;
- repeated jams or stoppages;
- increased scrap rates.
Professional cleaning limits these frictions and ensures consistent performance, even in demanding production environments.
Reduce Breakdowns and Unplanned Downtime
Buildup is one of the main causes of premature equipment wear. Over time, it can lead to:
- overheating;
- abnormal vibrations;
- sensor malfunctions;
- premature wear of critical components;
- emergency stops or forced shutdowns.
A regular maintenance program drastically reduces unplanned downtime—often far more expensive than professional cleaning itself.
Meet Cleanliness and Safety Standards
Industries such as food processing, pharmaceuticals, plastics, wood, and metals must comply with strict standards. Failure to do so exposes the company to:
- regulatory non-compliance;
- contamination risks;
- loss of certifications;
- OHS risks (slips, flammable residues, etc.).
Specialized maintenance protects both legal compliance and workplace safety.
Critical Zones on a Production Line
Every line includes sensitive areas where contaminants accumulate more quickly or pose higher risks. Key elements to monitor include:
Conveyors and Feeding Systems
Frequently clogged by dust, chips, granules, food residues, or lubricants.
Motors, Bearings, and Gears
Particle buildup may cause overheating or loss of precision.
Sensors, Cameras, and Optical Systems
Deposits interfere with detection and cause repeated errors.
Production Heads (extruders, kettles, print heads, molds)
Critical for product quality: residues = defects, variations, or shutdowns.
Structures, Supports, Rails, and Retention Areas
Often overlooked internally yet essential for safety and long-term durability.
The Most Effective Professional Cleaning Techniques
Cleaning methods must be selected based on contaminants, materials, and equipment. Common expert techniques include:
Dry Ice Blasting (Cryogenic Cleaning)
- Non-abrasive, no water or chemicals.
- Ideal for sensitive surfaces, electronics, molds, optical systems.
- Enables deep cleaning without disassembly.
Water Jet or High-Pressure Washing
- Highly effective for grease, thick buildup, or hardened residues.
- Suitable for robust environments: steel, structures, heavy machinery.
Soda Blasting or Soft Abrasive Cleaning
- For resistant surfaces or stubborn contaminants.
- Good balance between efficiency and material preservation.
Ultrasonic Cleaning
- Recommended for precision parts or complex geometries.
Specialized Manual Cleaning
- Essential for targeted disassembly, inspection, and high-precision areas.
How to Properly Prepare for Production Line Cleaning
Plan Cleaning According to Production Cycles
Ideally during:
- planned shutdowns;
- preventive maintenance;
- low-load periods.
Identify Critical Areas to Prioritize
A preliminary audit helps:
- locate buildup zones;
- assess OHS risks;
- identify equipment requiring special treatment.
Secure the Environment
- LO/TO (lockout/tagout) procedures;
- electrical safety;
- proper ventilation;
- residue and waste management.
Choose the Right Method for the Contaminants
Selecting the proper cleaning technique is crucial to avoid abrasion, corrosion, or damage.
How Often Should You Clean a Production Line?
Frequency depends on:
- industry type (food: daily/weekly; plastics: weekly/monthly);
- production intensity;
- raw material type;
- equipment age;
- regulatory requirements.
In practice, companies combine:
- daily or weekly internal cleaning (surface-level, accessible zones)
- monthly, quarterly, or semi-annual professional maintenance depending on line complexity and constraints.
Why Outsource Industrial Cleaning?
Even with a competent internal team, several factors justify calling in specialists:
- advanced cleaning techniques not available in-house;
- professional-grade equipment (cryogenic, ultrasonic, abrasive);
- safe intervention meeting OHS standards;
- reduced downtime;
- deep cleaning impossible through routine internal processes.
Outsourcing also provides objective inspection, preventive insights, and full traceability of interventions.
Better Maintenance for Better Performance
Production line cleaning is not a secondary task—it is a direct investment in productivity, safety, and equipment lifespan. A strong maintenance program reduces unplanned downtime, improves product quality, and extends the life of your machinery.
With the right methods and specialized expertise, companies like Solutions Trexo play a crucial role in ensuring reliable, compliant, and high-performing operations.