Enhancing Hygiene, Safety and Maintenance Efficiency in Large Baked Goods Production Facility
Enhancing Hygiene, Safety and Maintenance Efficiency in Large Baked Goods Production Facility
In large food production facilities, maintenance teams must balance strict safety and hygiene expectations with the need to keep production equipment running on tight schedules. At a high-volume baked goods manufacturing plant, portable power access for maintenance and repair activities was creating recurring safety concerns, workflow delays, and rising MRO costs—particularly in dry production, packaging, and support areas.
To address these challenges, the facility partnered with KH Industries to standardize portable power access using industrial retractable cord reels designed to keep cables controlled, organized, and off the floor during maintenance activities.
The Problem: Temporary Power Was Creating Safety and Workflow Issues
Maintenance and engineering teams relied heavily on temporary power for inspections, adjustments, and minor repairs on production and packaging equipment. While necessary, traditional extension cords introduced multiple operational problems.
01
Trip and entanglement hazards
Portable cords stretched across walkways and around equipment during maintenance activities, increasing the risk of slips, trips, and near-miss incidents—especially during shift changes and production startup.
02
Inefficient maintenance workflows
Technicians spent unnecessary time locating outlets, pulling long extension cords, and coiling them back up after tasks were completed, delaying repairs and preventive maintenance activities.
03
Poor cord organization and storage
Cords were frequently stored improperly or left on carts and floors, leading to tangles, damage, and lost equipment between shifts.
04
High MRO replacement costs
Repeated twisting, pulling, and running cords through doorways and around machinery caused premature wear, electrical faults, and frequent cord replacement.
The Solution: Controlled Portable Power Using KH Industrial Retractable Cord Reels
KH Industries’ technical sales team worked with the facility’s maintenance and safety leaders to review.
The reels were mounted overhead — either on the ceiling or high on the wall — directly above workbenches, service bays, and equipment that required frequent power or air access.
- Typical maintenance tasks and power needs
- Areas where portable power was most frequently used
- Traffic patterns around production and packaging lines
- Mounting locations that would reduce floor-level cord exposure
- Standardization opportunities for maintenance equipment
Based on this assessment, KH Industries recommended a portable power management strategy centered on industrial retractable cord reels for dry and semi-restricted areas of the facility.
Ceiling Mounted KH Industrials RTA & RTB Series Cord Reels in Packaging and Logistics Areas
In dry production, packaging, and equipment service areas, overhead-mounted industrial cord reels were installed to provide controlled access to power for maintenance tools and portable lighting.
Benefits included:
- Cords deployed only when needed
- Automatic retraction after use
- Reduced cord exposure on floors and walkways
- Faster setup and tear down for maintenance tasks
Portable Maintenance Carts with Integrated Reels
Maintenance teams were equipped with mobile service carts featuring integrated KH Industries RTB Series retractable cord reels connected to an integral outlet box, allowing technicians to bring organized power access directly to the point of work.
This approach:
- Eliminated dragging cords from distant outlets
- Reduced cord tangling around equipment
- Improved efficiency during inspections and repairs
- Simplified storage between shifts
Standardized Cord Management Across All Shifts
By standardizing retractable reel use across maintenance teams, the facility reduced variation in how power cords were handled and stored.
Results included:
- More consistent safety practices
- Fewer damaged cords between shifts
- Improved accountability for maintenance equipment
The Results: Safer Work Areas and More Efficient Maintenance Operations
The new portable power approach delivered measurable improvements in safety, productivity, and cost control
01
Sfety Improveaments
- Significant reduction in trip and entanglement hazards
- Clearer walkways around active production equipment
- Improved alignment with internal safety policies
02
Maintenance Efficiency
- Faster response to equipment issues
- Reduced time spent managing extension cords
- Reduced time spent managing extension cords
03
MRO Cost Reduction
- Lower frequency of cord replacement due to reduced wear and damage
- Fewer emergency cord purchases and tool downtime
- Better utilization of existing maintenance assets
Why Choose Retractable Cord Reels for Food Production Facilities
This case study highlights how portable power management directly affects safety and maintenance efficiency, even in some food production environments.
Retractable cord reels provide a practical way to control cords, reduce hazards, and support consistent maintenance workflows without interfering with production schedules. This application demonstrates how industrial cord reels add value beyond basic extension cords. For food manufacturing operators, it shows how working with KH Industries delivers both durable products and application-specific technical guidance
KH Industries designs and manufactures industrial retractable cord reels and portable power solutions for demanding environments, including food production and packaging facilities. Through its technical sales team, KH Industries works with distributors and end users to recommend reel configurations and mounting options that improve safety, organization, and uptime
