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Exelerate™ TUFSOIL provides safer and faster application in addition to improved cleaning outcomes in industrial fryer soils when compared to a competitor’s product



VALUE DELIVERED


$56,100
Potential Annual Productivity Gains


$26,374
Estimated Annual Savings

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Background

A major potato processing plant in North America produces battered and shaped French fries sold to major foodservice and retail suppliers across the globe. The battered product lines and form lines have high amounts of carbohydrate, oil, and sugar soils that build up on and around the fryer area.

The plant manufactures product for 21 continuous days and has a 24-hour shutdown period to clean. The customer is currently using a competitor’s high alkaline, ready-to-use gel cleaner and while they are meeting expected cleaning outcomes, they are experiencing several issues:

  • Applying the competitor’s gel cleaner takes 1 hour per fryer due to slow dispensing and limited surface coverage due
    to high viscosity.
  • The high viscosity of the competitor’s gel cleaner clogs and damages the dispensing equipment causing downtime due to constant repairs and maintenance.
  • The high alkaline concentrations in the competitor’s gel cleaner are known to have caused injuries and respiratory irritation to users applying it.

After consulting with the Ecolab Account Manager, the plant management decided to use Exelerate™ TUFSOIL, a ready-to-use heavy duty gel cleaner and degreaser, to tackle their hard-to-remove oils and French fry soils. The success criteria were the following:

  • Reduce the time spent applying the chemistry on the surfaces and minimize downtime due to dispensing equipment maintenance.
  • Reduce the overall time spent cleaning the fryer line and achieve equal or improved cleaning results when compared to the competitor’s gel cleaner.
  • Enhance worker safety during application of chemistry and reduce respiratory hazards.

Exelerate™ TUFSOIL’s fluorescent green dye was positively received by operators because it allowed them to clearly visualize where the product had been applied, avoiding overuse, and ensuring that it was properly rinsed.

Exelerate™ TUFSOIL

Results

Implementing Exelerate™ TUFSOIL allowed the customer to maintain cleaning performance while reducing the fryer cleaning time by close to 1 hour, providing the plant with the potential to start production earlier, conduct additional preventive maintenance work, or carry out cleaning and sanitation in other areas.

Exelerate™ TUFSOIL’s fluorescent green dye was positively received by operators because it allowed them to clearly visualize where the product had been applied, avoiding overuse, and ensuring that it was properly rinsed.

Finally, users noted no odor while using Exelerate™ TUFSOIL, enhancing worker safety and reducing respiratory irritation when compared to the competitor’s product.

By efficiently removing carbohydrate, oil, and sugar soils, Exelerate™ TUFSOIL helps reduce soil build-up and helps reduce risks of fryer fires after a clean-up.

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Conclusion

By switching to Exelerate™ TUFSOIL and implementing it as part of their fryer cleaning program, the plant was able to achieve its goals of reducing the overall time spent cleaning the fryers, enhancing worker safety, and achieving satisfactory cleaning outcomes.


 

CONVERSION SAVINGS

 

Productivity icon
Human Health and Safety icon

0 Operators
experiencing respiratory irritation


~1 Hour
reduction in fryer cleaning per line


10 Minutes
reduction in downtime due to dispensing equipment failure


~30%
potential reduction in volume application vs competitor’s ready-to-use gel cleaner


Download Exelerate™ TUFSOIL Potato Processing eRoi Case Study

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