In food processing environments, the act of moving product is rarely neutral. Conveying systems exert forces that can subtly or dramatically alter product quality before it ever reaches packaging. For processors handling fragile or irregular ingredients such as cereals, grains, nuts, frozen foods, pet food, or specialty powders, these forces can translate into breakage, dust generation, inconsistent flow, or contamination risks. As food safety requirements tighten and product differentiation increasingly depends on appearance, texture, and uniformity, conveyance has become a critical point of control rather than a background utility. For many processors, this has elevated gentle, controlled conveying from a ‘nice to have’ to a core design requirement.

This shift has driven renewed attention toward conveying technologies designed to not just transport material efficiently, but to do so gently, hygienically, and predictably across complex plant layouts. Among these, modern tubular drag conveying systems illustrate how mechanical design choices, cable construction, disc materials, sealing strategies, and cleaning access directly influence both product integrity and operational resilience.

Why Gentle Handling Matters More Than Ever

The consequences of aggressive or poorly controlled conveying are cumulative. Minor abrasion at transfer points can break products down into fine particles that alter bulk density or create dust hazards. Those seemingly minor changes can cascade into off-spec batches and housekeeping challenges. Repeated impacts can fracture fragile pieces, degrade visual appeal, and can introduce variability that complicates downstream weighing or blending. Over time, these effects erode yield and consistency, even if no single failure is dramatic enough to trigger immediate corrective action.

Gentle handling is therefore less about moving slowly and more about moving intentionally. Conveying systems must maintain steady, controlled motion that minimizes differential forces within the product stream. Cable-driven tubular drag systems embody this principle by maintaining steady, cable-pulled motion around bends and elevation changes without relying on high velocities or abrupt transfers. This is particularly important when ingredients vary in size, shape, or moisture content, as uneven flow can lead to segregation or bridging. A system engineered for gentle conveyance treats the product as something to be preserved, not simply moved.

Sealed Conveyance, Hygienic Design, and Practical Cleanability

In parallel with growing concerns around product quality, food processors face escalating expectations related to sanitation and environmental containment. Open conveying methods, such as belts or bucket elevators, introduce multiple exposure points where products can escape or where airborne contaminants may enter the product stream. Even when guarded or partially enclosed, these systems often rely on external housekeeping and frequent manual intervention to maintain acceptable hygiene levels, increasing both labor demands and variability in sanitation outcomes.

Fully enclosed conveying designs address many of these risks at the source. By sealing the product path from inlet to discharge, they limit exposure to the surrounding environment, prevent ingredient loss, and reduce the number of surfaces that require secondary cleaning. In practice, this often translates into shorter changeovers and less time spent cleaning surrounding equipment and floors. Just as importantly, enclosure simplifies validation. When the product only contacts defined, cleanable internal surfaces, sanitation protocols become more repeatable, auditable, and easier to align with food safety and quality programs. For processors managing multiple recipes, this containment can significantly reduce the complexity and downtime associated with changeovers, shifting sanitation efforts away from entire rooms or conveyor corridors and back to the conveying system itself.

However, enclosure alone is not sufficient. Cleaning requirements vary widely across food applications, with some operations relying primarily on dry cleaning while others require frequent wet cleaning to manage carryover. Conveying systems must therefore support a range of sanitation strategies without forcing processors into rigid, one-size-fits-all procedures. Designs that incorporate modular cleaning tools, such as wiper flights, scraper discs, brushes, or sponge elements, allow sanitation methods to be tailored to specific products, risks, and production schedules.

In wet clean applications, the ability to flood, rinse, and dry the conveying path without disassembly can dramatically reduce labor and shorten sanitation windows. Features such as integral drains and sealed connections further support Clean-In-Place (CIP) protocols by eliminating areas where moisture or residue might accumulate. When these capabilities are engineered into the system architecture from the outset, sanitation becomes a predictable, controlled process rather than a reactive response to contamination concerns. It also helps processors avoid unplanned downtime tied to failed inspections or inconsistent manual cleaning.

Friction, Wear, and the Hidden Costs of Poor Flow Control

Even in enclosed systems, internal friction remains a primary driver of maintenance and downtime. As the product moves through horizontal runs and directional changes, resistance between the conveying elements and the tube wall accumulates. Excessive friction accelerates wear, increases power demand, and can lead to cable stretch or component failure if not properly managed.

Modern tubular drag conveyors address this through material selection and geometry. Self-lubricating ultra high molecular weight polyethylene discs, for example, reduce contact friction while maintaining enough surface engagement to move product efficiently through bends, where resistance and wear are typically highest. Lower friction not only extends component life but also greatly diminishes unexpected downtime and the frequency of component replacement, stabilizing conveying behavior and reducing the likelihood of surging or inconsistent discharge rates. By minimizing wear at these points, processors can reduce unexpected downtime for component replacement and cable adjustments.

This focus on internal mechanics highlights an often-overlooked truth: gentle conveying is as much about protecting the equipment as it is about protecting the product. Systems designed to operate smoothly under sustained load demand less corrective maintenance and offer more predictable uptime.

Flexibility, Integration, and the Long View of Sanitary Conveying

Few food processing facilities are designed around straight lines, and fewer remain static over time. Conveying systems must navigate elevation changes, structural constraints, and evolving production demands while maintaining consistent performance and hygienic integrity. Technologies that support circuitous routing, allowing conveyors to move horizontally, vertically, and around obstacles, give engineers greater freedom to design layouts that respond to real world conditions rather than forcing processes to conform to rigid equipment footprints.

This flexibility has implications beyond spatial efficiency. When a single enclosed conveyor can replace multiple open belts or bucket elevators, processors reduce transfer points, simplify control logic, and limit the number of surfaces exposed to the production environment along the entire conveying circuit. For example, a cereal producer might consolidate several bucket elevators and horizontal belts into a single CablePro™ loop that threads through existing structures while maintaining gentle handling. Fewer transitions mean fewer opportunities for product loss, contamination, and mechanical wear, all of which contribute to more predictable sanitation routines and long-term reliability.

In this context, cable-driven tubular drag conveyors have gained traction because they pair routing flexibility with fully enclosed, hygienic construction. Systems such as Hapman’s CablePro™ Tubular Drag Conveyor illustrate how these attributes can be integrated without compromising gentle handling or cleanability. By combining sealed stainless-steel tubing with a pre-stretched, food-grade coated cable and low-friction UHMW discs, the system maintains steady product movement through complex paths while minimizing internal wear. Features such as automatic cable tensioning further stabilize performance over time, reducing maintenance interventions that can disrupt production schedules and compromise overall line availability.

Equally important is how these systems support varied sanitation strategies. The ability to configure dry or wet cleaning accessories, along with sealed connections and integral drains, allows processors to align cleaning protocols with specific product risks and operational rhythms rather than forcing every operation into the same sanitation model. In practice, this adaptability can shorten changeovers, reduce downtime, and improve confidence in sanitation outcomes.

Stepping back, the value of flexible, enclosed conveying is not tied to any single feature or product. It reflects a broader shift in how processors evaluate material handling decisions. Conveying systems are no longer judged solely by throughput or horsepower, but by how well they protect product quality, support food safety programs, and adapt as facilities grow or change. Equipment that can move gently, clean thoroughly, and integrate seamlessly into complex layouts becomes an enabler of long-term operational resilience rather than a constraint. For processors facing tightening food safety regulations and pressure to maintain product quality while running harder and longer, systems like CablePro™ are positioned to help them stay ahead, delivering gentle, enclosed conveyance with cleaning regimes that can adapt as products, allergens, and regulatory requirements change.

As food processors continue to balance efficiency, safety, and product integrity, conveying technologies that embody these principles will play an increasingly central role, quietly shaping outcomes not just at the point of transfer, but across the entire production lifecycle.

TORONTO, ON – August 11, 2026 – Gay Lea Foods Co-operative Limited (“Gay Lea Foods”) today announced an investment of more than $200 million to significantly expand its Clayson Road dairy manufacturing facility in Toronto.

This investment will help address the national cottage cheese shortage and create additional capacity across the farmer-owned, Canadian dairy co-operative’s growing portfolio of high-protein dairy products.

The project marks the first major milestone in Gay Lea Foods’ approximately $450-million Network for Growth strategy – a multi-year investment to strengthen and modernize the co-operative’s Canadian manufacturing network, ensuring it is well positioned to meet evolving consumer demand while creating long-term value for its farmer members.

Cottage cheese has experienced incredible growth as Canadians seek nutritious, affordable health and wellness options to support evolving lifestyles. The expansion responds to that momentum and signals Gay Lea Foods’ ambition to help lead the next chapter of cultured dairy in Canada.

“This investment reflects our confidence in the future of Canadian dairy and in Gay Lea Foods’ role in helping shape it,” said Suzanna Dalrymple, President and Chief Executive Officer of Gay Lea Foods. “That future will be built on Canadian dairy farms and in modern processing facilities equipped to respond to evolving consumer preferences.”

By expanding production across its high-protein dairy portfolio, including cottage cheese, and strengthening processing capabilities, Gay Lea Foods is creating opportunity for our farmer-members and employees, supporting the Canadian dairy industry and advancing the co-operative’s purpose to enrich life with dairy.

The expansion will introduce advanced processing technology and modern manufacturing capabilities designed to increase production capacity, strengthen productivity and enhance operational flexibility. Together, these investments will help position Gay Lea Foods to respond to evolving market needs while supporting the co-operative’s long-term growth.

The expansion, to be complete in 2028, will create up to 75 new positions at the Clayson facility, adding skilled manufacturing jobs and contributing to the local economy.

“For more than 65 years, our farmer-members have invested to build a stronger future for Canadian dairy,” said Andrew Henderson, Chair of the Board at Gay Lea Foods.  “Expanding a facility that transforms Canadian milk into a product sold exclusively to Canadian consumers, is a natural extension of our co-operative’s legacy.”

Richmond, B.C. (August 11, 2026) — With wildfire activity intensifying across British Columbia, WorkSafeBC is reminding employers to review their emergency evacuation plans and prepare for situations where workers may need to evacuate a workplace. When local emergencies occur, including wildfires, employers should be prepared to support the safe evacuation of workers. 

“Employers should understand the risks that may impact their workplaces and ensure they have appropriate emergency procedures in place,” says Todd McDonald, Head of Prevention Services at WorkSafeBC. “Emergencies and disasters can happen any time and without warning. The more prepared you are for them, the better you’ll be able to respond.”  

Preparing for an evacuation 

• Identify when workers may need to evacuate. Consider wildfires and other emergencies that could affect the workplace, including risks specific to the location. 

• Have clear evacuation routes. Identify primary and alternate routes to safely leave the worksite and make sure exits are clearly marked, well-lit and free of obstructions.  

• Have a way to alert workers. Make sure workers know how they will be notified if they need to evacuate and what an evacuation alert or order means. 

• Assign responsibilities. Make sure workers know who is coordinating the evacuation and who will help others get to safety.

• Plan for shutting down equipment and work processes. Identify what may need to be shut down, how it can be done safely, and who is responsible. Consider materials or processes that could become hazardous when exposed to fire. However, workers should not delay evacuation to shut down equipment or complete other tasks when there is an immediate threat to their safety.

• Plan for everyone. Consider the needs of workers, visitors and others who may need assistance during an evacuation, including people with disabilities and those who do not speak English. 

• Keep workers informed and prepared. Review the plan with workers, provide training and hold evacuation drills at least once a year. Discuss emergency plans seasonally or when the potential for an emergency increases. 

Protecting workers from wildfire smoke 

Wildfire smoke can affect workers even when a fire is not close to the workplace. Employers should monitor local air quality and adjust work as conditions change. This may include relocating or rescheduling work, reducing strenuous activity and taking steps to improve indoor air quality. 

WorkSafeBC has resources to help employers prepare for wildfire season, including information on emergency planning and response, emergency evacuation planning and wildfire smoke.

Milwaukee, WI – PFlow Industries, the pioneer in vertical reciprocating conveyor (VRC) technology, highlights its DeckLock™ Safety System, which provides critical protection in material lifting environments. The DeckLock system is designed to eliminate accidents caused by carriage overload, protecting workers, valuable materials, and machinery while supporting efficient workflow for industrial users.

Built for maximum reliability, DeckLocks automatically extend at critical upper levels to provide added prevention against unintended or uncontrolled carriage descent, while keeping the deck level with the floor for safe forklift loading and unloading. This exclusive solution is available in gate-operated mechanical, pneumatic, and electric versions, each engineered for seamless integration with PFlow VRC solutions. When the carriage reaches an upper level, the DeckLocks engage automatically before the gate opens and retract when it closes—delivering added safety exactly when it matters most.

Electrical DeckLocks utilize a gate-mounted electrical switch paired with an electric actuator, column-mounted for all 2- and 4-post mechanical VRCs. They may be controlled with or without a PLC (programmable logic controller), and they feature adjustable limit switches, a removable pivot pin for maintenance, and terminal strips for pre-wiring. Electrical DeckLocks are suitable for applications with non-PFlow gates or multiple gates per floor level, with the exception of limited outdoor environments.

Pneumatic DeckLocks combine electrical solenoid valves with a pneumatic actuator cylinder. Available for all 2- and 4-post mechanical VRCs, pneumatic versions are compatible with limited outdoor applications above 32°F and are approved for explosion-proof environments. Mechanical DeckLocks employ a gate-mounted cable mechanism that directly actuates the lock cam, and are ideal for 2-post VRCs with single gates per floor level.

The DeckLock Safety System is optional, providing an extra layer of security beyond the substantial safety measures built into every PFlow VRC. While mechanical VRCs rely on spring-set brakes sized to deliver at least 150% of maximum capacity, wear or insufficient maintenance can diminish effectiveness. Additionally, inadvertent overload has the potential to lead to dangerous carriage descent and brake slippage. The patented DeckLock design provides critical, exclusive protection under these overload and brake-wear conditions, delivering confidence and security to a variety of operations.

For more information, visit https://www.pflow.com/safety-gates/decklock/.