Why machine blades are important

Before we delve into the causes of machine blade failure, we want to emphasise just how important blades are.

As they’re a small part in an overall processing or packaging operation, they are often overlooked – but they really shouldn’t be.

Machine blades play a critical part in the efficiency, quality, and results of your processing operations. Using quality, well-maintained blades can make your processing and/or packaging operations more efficient, and thus more profitable.

It pays – literally – to prevent machine blade failure.

What are the consequences of machine blade failure?

There are more consequences than many people realise when machine blades fail.

These consequences can include:

• Damage to the machinery to which the blades are fitted.
• Damage to the produce or packaging that is being cut – sometimes resulting in a total loss of that produce or packaging material.
• Downtime – sometimes including the complete shut-down of your operations, costing you significant sums of money.
• The cost of replacement blades.
• The cost of additional labour time for repair.
• The cost of additional components/parts if they were damaged by the machine blade failure.

That’s just the tip of the iceberg, too. Should machine blade failures occur frequently enough, you can end up missing production deadlines – putting your relationship with your customers at risk.

As you can see – it’s imperative that you prevent machine blade failure as much as possible.

What are the common causes of machine blade failure?

Okay, so what are the common causes of failure, and what are their solutions? There are a number of causes which occur on a regular basis – however, it’s generally straightforward to resolve or prevent these causes, as you’ll see detailed below.

Problem: Incorrect usage

If you’re using a machine blade for something for which it was not designed for – it will almost inevitably break.

For example, if you’re attempting to process carcasses with blades that are not designed for that purpose, you run the risk of the blade snapping or failing when it is unable to withstand the loads it’s being subjected to.

Here at MRMK, we understand that every industry has different cutting requirements. That’s why we offer blades that are tailored to industries as varied as baking, dairy processing, meat processing, tobacco processing, pharmaceuticals and more.

We also offer blades that are designed specifically for certain purposes, such as:

• Circular knives.
• Packaging knives.
• Thermoforming machine blades.
• Tray seal knives.
• Converting knives.
• And more…

Solution: Purchase blades from a manufacturer with industry knowledge

The easiest way to avoid your machine blades being subjected to incorrect usage is to purchase your blades from a manufacturer that has a deep and acute understanding of your particular industry.

For example, here at MRMK we give great thought to the different applications our blades and knives can be subject to and design and manufacture them accordingly.

We also have decades of combined experience supplying industrial knives and blades to a broad range of industries, including; bakery, convenience foods, dairy, meat processing, pharmaceuticals, tobacco, and many more.

As such, we know the types of stresses and loads our blades are likely to be subjected to.

Problem: Lack of running in

Whenever a blade is fresh, it’s advisable to ensure it is ‘run in’ before you subject it to your usual full production speed/production cycle.

By giving your machine blade time to bed in, you’ll allow the sharpened section of the blade to ‘wear in’. Although it depends on the exact piece of machinery being used, you should consider running the blade at 50% reduced feed rate for around five minutes, before then moving up to full speed.

Solution: Buy quality-assured blades and knives

In addition to properly ‘running in’ your blades, you can make the entire process by purchasing your machine blades from a manufacturer that properly quality assesses each and every blade that leaves their factory.

This means you’ll know that the blades you receive are perfect and not like to cause any issues whilst they’re being run in.

Problem: Incorrect fitting

Another common cause of machine blade failure is the blade not being correctly fitted in the first place.

If the blade is not positioned correctly, is subject to too much (or too little) tension, or set at the incorrect angle, you increase the chances of it failing.

Always ensure that your machine blades are fitted as per the instructions provided by the manufacturer of the machinery.

Blades can also fail if they aren’t manufactured to OEM-equivalent standards. This is particularly the case with cheap, generic blades. We’d recommend choosing a blade from a manufacturer that has a track record of producing OEM-quality (or higher) blades.

Solution: Buy precision-engineered blades

Avoid improperly fitting machine blades by only buying ones that have been designed and manufactured to the tightest tolerances.

What’s more, if you’re buying blades for specific machines, then you don’t want to simply buy generic replacement blades, but blades which have been specifically designed to fit that particular machinery.

Here at MRMK, that’s the approach we take, precision engineering each and every one of our blades and – where a blade is designed for a specific piece of machinery – ensuring it’ll fit to perfection.

Problem: Poor maintenance

Should you fail to adequately maintain your machine blades, you’ll increase the chance of them failing.

Blades should be regularly inspected and cleaned. This will not only prolong the service life of the blade but will ensure the blade is cutting as well as possible – improving the quality of your output (be it food, packaging or other substances).

Depending on what your blades are cutting, they may also benefit from regular lubrication.

Solution: Regrind your blades when necessary

In addition to regularly inspecting and cleaning your blades, you can prolong their useful service life – and prevent premature failure – by having them reground as soon as their cutting performance starts to deteriorate.

Here at MRMK, we offer a regrinding service which can totally refresh your knives.

Problem: Poor quality

The main cause of machine blade failure is ultimately poor quality design, materials, and manufacture.

Whilst it may be tempting to cut costs and purchase cheap, generic machine blades, you’ll quickly find that it’s a false economy.

Poor quality blades – which are bound to fail – will end up costing you more in terms of stoppages, downtime, damaged machinery and products. Instead, it’s better to spend slightly more and end up with machine blades that provide a long service life with consistent cut quality.

Solution: Buy high-quality industrial blades

This may seem like an obvious point, but if you want to prevent machine blade failure, you should buy the best possible blades you can.

In fact, whilst quality machine blades may cost a little more than generic alternatives – downtime of your production can cost you a lot more.

As one of our customers recently said: “We don’t focus purely on cost; we need to keep the business running and if that means paying for better quality then we will. We can’t be without a production line”.

If you can’t be without a production line, then you’ve got to buy quality. But, how can you tell if a machine blade is any good or not?

Well, look for machine blades that are precision engineered, made from a high-grade of hardened steel, and that are available with a variety of coatings and other options.

Don’t forget to check out a blade manufacturer’s service levels too. That can make a huge difference when you need new blades in a hurry.

Buy the best, buy MRMK

Here at MRMK, we’ve made it our mission to transform the way machine blades are designed, manufactured and sold.

We make blades that are of OEM quality (and often higher) but at a fraction of the cost. We also endeavour to offer the very best custom service. So, whether you require a completely custom blade or you need a blade in a hurry – we’ll always try to achieve this for you.

Want to know more? Then speak to our friendly, expert team who’ll be happy to discuss your machine blade requirements.

Explore MRMK’s range of machine blades now

For more machine blade buying guides, advice and information, read the MRMK News and Insights Hub…

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