Food Engineering logo
  • Sign In
  • Create Account
  • Sign Out
  • My Account
  • NEWS
  • PRODUCTS
  • TOPICS
  • EXCLUSIVES
  • MEDIA
  • FOOD MASTER
  • EVENTS
  • RESOURCES
  • EMAGAZINE
  • SIGN UP!
cart
facebook twitter linkedin youtube
  • NEWS
  • Latest Headlines
  • Manufacturing News
  • People & Industry News
  • Plant Openings
  • Recalls
  • Regulatory Watch
  • Supplier News
  • PRODUCTS
  • New Plant Products
  • New Retail Products
  • TOPICS
  • Alternative Protein
  • Automation
  • Cannabis
  • Cleaning | Sanitation
  • Fabulous Food Plants
  • Food Safety
  • Maintenance Strategies
  • OEE
  • Packaging
  • Sustainability
  • More
  • EXCLUSIVES
  • Plant Construction Survey
  • Plant of the Year
  • Sustainable Plant of the Year
  • State of Food Manufacturing
  • Top 100 Food & Beverage Companies
  • MEDIA
  • Podcasts
  • Videos
  • Webinars
  • White Papers
  • EVENTS
  • Food Automation & Manufacturing Symposium and Expo
  • Industry Events
  • RESOURCES
  • eNewsletter
  • Custom Content & Marketing Services
  • FE Store
  • Government Links
  • Industry Associations
  • Market Research
  • Classified Ads
  • EMAGAZINE
  • eMagazine
  • Archive Issue
  • Advertise
Food Engineering logo
search
cart
facebook twitter linkedin youtube
  • Sign In
  • Create Account
  • Sign Out
  • My Account
Food Engineering logo
  • NEWS
    • Latest Headlines
    • Manufacturing News
    • People & Industry News
    • Plant Openings
    • Recalls
    • Regulatory Watch
    • Supplier News
  • PRODUCTS
    • New Plant Products
    • New Retail Products
  • TOPICS
    • Alternative Protein
    • Automation
    • Cannabis
    • Cleaning | Sanitation
    • Fabulous Food Plants
    • Food Safety
    • Maintenance Strategies
    • OEE
    • Packaging
    • Sustainability
    • More
  • EXCLUSIVES
    • Plant Construction Survey
    • Plant of the Year
    • Sustainable Plant of the Year
    • State of Food Manufacturing
    • Top 100 Food & Beverage Companies
  • MEDIA
    • Podcasts
    • Videos
    • Webinars
    • White Papers
  • FOOD MASTER
  • EVENTS
    • Food Automation & Manufacturing Symposium and Expo
    • Industry Events
  • RESOURCES
    • eNewsletter
    • Custom Content & Marketing Services
    • FE Store
    • Government Links
    • Industry Associations
    • Market Research
    • Classified Ads
  • EMAGAZINE
    • eMagazine
    • Archive Issue
    • Advertise
  • SIGN UP!
Automation

TECH FLASH

Calculating the ROI of pneumatic conveyers

Pneumatic conveyers can help operations engineer hazards and ergonomic inefficiencies out of process manufacturing.

By Shane O'Halloran
Calculating the ROI of pneumatic conveyers
July 30, 2013

According to OSHA, “manual material handling is the principle source of compensable injuries” in the goods producing industry. And when workplace injuries occur, workers aren’t all that is hurt—so are profits. It is estimated $250 billion is lost due to workplace injuries and illnesses every year. Processors know workplace injuries and illnesses are counterproductive to the bottom line, but may be hesitant to adopt new technologies without proof of sufficient return on investment (ROI).

Calculating the ROI of pneumatic conveyers
Using pneumatic conveying systems to eliminate ergonomic issues and potential costs associated with injury often results in increases in productivity. Source: Vac-U-Max

Ideally, hazards would be engineered out of the process, but that isn’t always possible. However, use of a pneumatic conveying system can reduce fall hazards and back injuries as well as control fugitive dust.

Pneumatic conveyers use vacuum technology to gently and quickly convey material from point to point. Suitable for batching, conveying and weighing dry materials from fine powders to plastic pellets and caps, they consist of five pieces of equipment: a pick-up point, convey tubing, a vacuum receiver, a vacuum producer and a control module. Systems also may offer semi-automation or complete automation, but all offer improved safety.

While no single formula exists for determining ROI of engineering a safety hazard out of a process, data easily supports the contribution of pneumatic conveyers to the bottom line through reduced or eliminated hazards and gained productivity. OSHA’s $afety Pays (SP) worksheet is one tool that helps managers quantify the benefit of hazard reduction/elimination. The worksheet estimates that, with a 5 percent profit margin, the indirect costs of back injuries average in excess of $30,000 and require additional sales of $672,122 to recoup losses. These costs should be taken into account when determining ROI.

Ergonomic improvements can enhance production significantly. The American Society of Safety Engineers (ASSE) offers a worksheet for calculating ROI of ergonomic improvements using the following formula: Projected productivity impact percentage = (total time savings)/(total operations time)x100. Annual savings = (productivity impact)x(annual direct cost), and Payback period in years = (cost of improvement)/(annual savings).

In one example, an ergonomics team was able to save .4 seconds per repetition of a particular task by moving an inconveniently located screw bin closer to the worker, resulting in a 32 minute per shift time savings. But the team wanted to save even more time and money, so it investigated installing a self-feeding driver at a cost of $2,500. The self-filling driver would eliminate three tasks and 3.2 seconds per task repetition in a 12-second task cycle.

Using the equations above, we find the projected productivity estimate is 27 percent. ASSE uses a conservative productivity impact of 17 percent (by estimating only 2.1 seconds per task cycle removed), and multiplies that by the current annual direct cost of $36,250 (direct labor cost plus benefits burden) to arrive at an annual savings of $6,162. That savings represents a payback period of only .4 years, or 4.8 months, and a three-year ROI of 639 percent.

Translated to pneumatic conveyers, consider the common scenario of needing to transport material to a raised platform and dump it into a hopper. This process represents not only ergonomic hazards but fall hazards and the possibility of fugitive dust. A proactive executive will seek to eliminate these hazards before an accident occurs, and would benefit from the ability to undertake an ROI analysis like the one above. Even if the time required to complete a task stays the same, the reduction of operator hazard and eliminating the possible need to hire another operator can represent significant ROI.

For more information on pneumatic conveyers, contact Doan Pendleton: info@vac-u-max.com.

KEYWORDS: conveying

Share This Story

Looking for a reprint of this article?
From high-res PDFs to custom plaques, order your copy today!

Recommended Content

JOIN TODAY
to unlock your recommendations.

Already have an account? Sign In

  • Global Organic Food & Beverage Market to Grow

    Global Organic Food & Beverage Market to Grow

    With a CAGR of 12.07%, Bonafide Research estimates this...
    Latest headlines
  • skilled MEP worker

    Predicting Food and Beverage Manufacturing Trends for 2024

    The two words that should be kept in mind are labor and...
    Automation
    By: Derrick Teal
  • cleaning and sanitation

    The basics of cleaning and sanitation in food plants

    Sanitation maintains or restores a state of cleanliness...
    Food Safety
    By: Richard F. Stier
Subscribe For Free!
  • eMagazine
  • eNewsletter
  • Online Registration
  • Manage My Preferences
  • Customer Service

Food Plant Openings and Expansions May 2025

Food Plant Openings and Expansions May 2025

OT Cybersecurity Vulnerabilities in Food Manufacturing Facilities

OT Cybersecurity Vulnerabilities in Food Manufacturing Facilities

Understanding Impacts of OT Cybersecurity Events in Food Manufacturing

Understanding Impacts of OT Cybersecurity Events in Food Manufacturing

Food Plant Openings and Expansions April 2025

Food Plant Openings and Expansions April 2025

More Videos

Popular Stories

Vilter IHP in plant

Industrial Heat Pumps: Sustainable Energy Solutions for Now and the Future

FMTE Formed by Four Food Manufacturing Companies

Coalition Unites Europe’s Food Manufacturing Technologies and Equipment Sector

Sanitation worker spraying water

Fighting the Foodborne Bacteria War with Cleaning and Sanitation

CHECK OUT OUR NEW ESSENTIAL TOPICS

Alternative ProteinAutomationCleaning/SanitationFabulous Food Plants

Food SafetyMaintenance StrategiesOEE

PackagingSustainability

Events

June 17, 2025

Refrigerated & Frozen Foods’ State of the Cold Chain

Kelley Rodriguez, Editor in Chief of Refrigerated & Frozen Foods, will be joined in this 60-minute webinar by industry experts to help unpack the latest research.

January 1, 2030

Webinar Sponsorship Information

For webinar sponsorship information, visit www.bnpevents.com/webinars or email webinars@bnpmedia.com.

View All Submit An Event

Products

Recent Advances in Ready-to-Eat Food Technology

Recent Advances in Ready-to-Eat Food Technology

See More Products

Plant of the Year

Related Articles

  • factory food engineering green roi

    Green Initiatives: Making the Leap to ROI

    See More
  • Food producer uses pneumatic conveying system to handle 20 tons of baker’s-like flour

    See More
  • Tubular Cable Conveyers

    Tubular cable conveyers

    See More

Related Products

See More Products
  • food-book.gif

    The 10 Principles of Food Industry Sustainability

See More Products
×

Elevate your expertise in food engineering with unparalleled insights and connections.

Get the latest industry updates tailored your way.

JOIN TODAY!
  • RESOURCES
    • Advertise
    • Contact Us
    • Food Master
    • Store
    • Want More
  • SIGN UP TODAY
    • Create Account
    • eMagazine
    • eNewsletter
    • Customer Service
    • Manage Preferences
  • SERVICES
    • Marketing Services
    • Reprints
    • Market Research
    • List Rental
    • Survey/Respondent Access
  • STAY CONNECTED
    • LinkedIn
    • Facebook
    • YouTube
    • X (Twitter)
  • PRIVACY
    • PRIVACY POLICY
    • TERMS & CONDITIONS
    • DO NOT SELL MY PERSONAL INFORMATION
    • PRIVACY REQUEST
    • ACCESSIBILITY

Copyright ©2025. All Rights Reserved BNP Media.

Design, CMS, Hosting & Web Development :: ePublishing

Food Engineering logo
search
cart
facebook twitter linkedin youtube
  • Sign In
  • Create Account
  • Sign Out
  • My Account
Food Engineering logo
  • NEWS
    • Latest Headlines
    • Manufacturing News
    • People & Industry News
    • Plant Openings
    • Recalls
    • Regulatory Watch
    • Supplier News
  • PRODUCTS
    • New Plant Products
    • New Retail Products
  • TOPICS
    • Alternative Protein
    • Automation
    • Cannabis
    • Cleaning | Sanitation
    • Fabulous Food Plants
    • Food Safety
    • Maintenance Strategies
    • OEE
    • Packaging
    • Sustainability
    • More
  • EXCLUSIVES
    • Plant Construction Survey
    • Plant of the Year
    • Sustainable Plant of the Year
    • State of Food Manufacturing
    • Top 100 Food & Beverage Companies
  • MEDIA
    • Podcasts
    • Videos
    • Webinars
    • White Papers
  • FOOD MASTER
  • EVENTS
    • Food Automation & Manufacturing Symposium and Expo
    • Industry Events
  • RESOURCES
    • eNewsletter
    • Custom Content & Marketing Services
    • FE Store
    • Government Links
    • Industry Associations
    • Market Research
    • Classified Ads
  • EMAGAZINE
    • eMagazine
    • Archive Issue
    • Advertise
  • SIGN UP!