Article
Why Food and Beverage Processors Need the Certainty of Schebler
To ensure worker and consumer safety, food and beverage processors operate in one of the most tightly regulated manufacturing environments in the world. From strict sanitation requirements to round-the-clock production schedules, facilities depend on reliable thermal processes — boilers, ovens, dryers, fryers and emergency generators — to keep products moving safely from raw ingredients to finished goods. But all that heat, smoke and fumes need to go somewhere. Which is why properly designed chimney and exhaust systems are critical. Failure in even one area can endanger workers and result in downtime, product loss or regulatory action.
Air and Exhaust Challenges in Food & Beverage Processing
High-quality chimney and exhaust systems are necessary for the following reasons, among others:
Energy consumption. Because of the large amounts of thermal energy required for heating, steam generation, drying, refrigeration and sanitation, food and beverage processing is one of the most energy-intensive segments of U.S. manufacturing. The resulting high exhaust temperatures require chimney systems to handle sustained thermal loads without leakage or degradation.
Corrosion prevention. Combustion exhaust in food plants often contains moisture, acids and grease vapors, especially in facilities producing meat, dairy, baked goods or fried products. These byproducts can accelerate corrosion and compromise exhaust integrity if materials and joints are not designed for the environment.
Environmental hazards. Under the FDA’s Food Safety Modernization Act (FSMA), processors must proactively control environmental hazards to avoid food contamination. Exhaust system leaks, soot or condensate can all become sanitation risks if not properly contained and directed. These concerns are why chimney and exhaust features, such as zero-leak performance and fire-rated construction, are vitally important. Exhaust systems must also be accessible for cleanouts to remove particulates and prevent build-up.
24-Hour performance. Many food and beverage plants operate around the clock. A failure in a boiler exhaust or emergency generator stack can shut down production lines, spoil product and disrupt cold-chain logistics. Systems must be durable, predictable and easy to integrate into both new construction and retrofit projects.
The Importance of Worker Safety
Proper venting is also critical to assure worker safety, as exhaust fumes can harm — and in some instances, kill — production line workers. For example, certain food processes, such as grain handling, sugar processing and powdered ingredient production, can create combustible dust hazards. OSHA notes that combustible dust explosions have caused numerous fatalities and facility losses in food manufacturing environments. These include 281 such incidents between 1980 and 2005 that led to 119 worker fatalities and 718 injuries.
Other worker threats include:
Carbon monoxide. Incomplete combustion or improperly vented boilers, heaters and generators can release carbon monoxide, which can quickly incapacitate or kill nearby workers. It’s been estimated that 50,000 people in the United States visit the emergency department each year due to accidental carbon monoxide poisoning.
Heat stress. When exhaust systems fail to properly remove hot combustion gases, ambient temperatures rise. This increases the risk of heat stress for workers.
Fire. Improper chimney systems can lead to excessive surface temperatures and exhaust leaks, increasing the risk of burns, material ignition and structural fires.
Oxygen Deficiency. Poorly vented combustion equipment can displace oxygen in enclosed spaces, creating oxygen-deficient environments that pose a risk of asphyxiation.
Reliable chimney and exhaust systems help maintain safe operating temperatures and proper venting, reducing the fire and explosion risk associated with combustion equipment.
The Schebler Advantage for Food & Beverage Processors
Schebler delivers the certainty food and beverage processors need, engineering systems for reliability, cleanliness, safety and compliance in demanding production environments. We also provide space-saving options, which are important for many building designs, including open-floor plans that offer limited structure to anchor ducts.
Our customized, factory-fabricated chimney and exhaust systems are designed to:
- Handle the high-temperature exhausts from fryers, ovens and boilers
- Maintain zero-leak performance to protect food safety and sanitation
- Resist corrosion from moisture and acidic exhaust byproducts
- Meet stringent UL listings and fire-resistance requirements
- Work within challenging spaces that require careful design, including systems with long drops or tension suspension
- Provide custom clean-out access for ongoing safety and long-term maintenance
- Minimize installation time and production line disruptions
Recommended Schebler Products
Schebler exhaust products ideal for food and beverage processors include the following, which range from non-condensing to UL 1978 grease duct systems.
P Series
These UL listed, lightweight chimney products offer low clearances, lower initial costs and multiple insulation options. They are the highest-quality general-purpose vents available.
FyreGuard®
These double-wall, round grease ducts increase usable space with zero clearance while improving fire safety. They are ideal for locations that require the removal of cooking/grilling fumes and particulates, such as restaurants and sports arenas.
SlimVent®
The industry’s only obround-shaped grease duct, the patented shape significantly reduces the necessary overhead space.
To learn how our exhaust solutions support food safety, regulatory compliance and uninterrupted production in food and beverage processing facilities, contact Schebler today.
