Case study: How an X-ray belt solution saved over $20,000

At this USDA facility, which handles poultry for a multinational meat processor and marketer, large chickens are processed into breast meat, filets and tenders. The poultry conveyor systems move at high speeds through the plant and are under stringent sanitation standards. In the eight X-ray belts at this facility, products are inspected and verified to be free of contaminants — an essential part of reducing food safety risks.

X-ray belt stretching risked sanitation

The facility manager noticed the X-ray belt continually stretched out at the pin holes, causing disengagement and frequent replacements. If left unchecked, product slippage at the entry point would become an issue, leading to greater sanitation risks, decreased throughput and a potentially reduced bottom line.

MIR’s solution

After conferring with MIR’s conveyor belting experts, the facility began the first trial run of a test belt to address the stretching problem. MIR tested a stronger belt material to achieve improved run time over the original 1-ply belt. However, fat build-up in the belt cover pockets made the belt too slick to pull the large breast meat up the entrance incline after multiple processing shifts. MIR then came back with a second test belt. On the second trial run, the facility manager was impressed with the aggressive profile, the color to contrast to the meat — and most importantly, the greatly increased belting lifespan.

Facility savings

The original X-ray belt had to be replaced every four weeks. The final belting solution from MIR lasted for 11 weeks on the production line, almost three times as long as the original. The USDA facility made the decision to switch to the MIR spec and change their replacement rotation to every eight weeks. The yearly cost for the original belt replacements had been $57,600. With fewer replacements and a longer lifespan, the improved X-ray belting solution reduced yearly spend to $37,573.44, saving the facility $20,026.56 per year in replacement costs.

Conveyor belting problems causing frequent replacements, mis-tracking or product damage are costly to your facility. Consider a belting audit with an experienced conveyor belting expert and stay ahead of conveyor belting issues. Sign up for the MIR Belting Audit™.

Case study highlights


Food Processing

Stretching on X-ray belt


MIR belting spec with aggressive profile


$20,026.56 in savings

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