203 Cooper Circle
Peachtree City, GA 30269
Phone: (770) 631-2100
Fax: (770) 631-2101
www.arrowhart.com
Case Study
Candy Manufacturing Facility Increases Safety, Saves Money with
Arrow Hart Audit
Comprehensive wiring devices audit contributes to increased efficiency, reduced downtime, code
compliance, and workplace safety recommendations for Georgia-based Crown Candy Corporation.
Cooper Wiring Devices’ Arrow Hart Engineering Sales team was recently tasked with conducting a
wiring devices audit for Crown Candy Corporation—an 85-year-old candy manufacturer in Macon, Ga.
The audit identified opportunities for improvement in the areas of employee and equipment safety,
compliance with codes and standards, reduced maintenance and downtime, and overall product
performance and longevity. With more than a century of leadership in designing and building the highest
quality wiring devices for the toughest applications, the Arrow Hart Engineering Sales team was able to
identify a range of areas for improvement, ultimately contributing to enhanced safety, productivity and
cleanliness for Crown Candy.
PROBLEM SOLVERS
The primary reason for a facility to undergo a complete wiring devices audit is to provide a safe and
productive work environment. Electrically unsafe conditions can contribute to workplace injuries,
manufacturing downtime and loss of productivity. Faulty electrical wiring and devices are consistently
among the top OSHA cited infractions and are a leading cause of workplace hazards. A proactive and
ongoing review of the quality and service of a facility’s wiring devices can enable cost-effective upgrades
that will improve safety and productivity while reducing downtime. For Crown Candy Corporation, these
were all competitive necessities that prompted the company to seek a professional audit of their
electrical infrastructure.
COMPREHENSIVE RECOMMENDATIONS
A detailed auditing process uncovered numerous opportunities for improvement within Crown’s
manufacturing plant. Arrow Hart’s recommendations included replacing standard devices with those
that are designed for use in more complex environments. This includes the replacement of receptacles,
plugs, connectors, switches and motor controls throughout the Crown facility. In Food & Beverage
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manufacturing environments, it is common for the electrical infrastructure to be exposed to water, hose
down, extreme temperatures, cleaning agents, and physical abuse. Standard industrial devices
repeatedly used in these harsh manufacturing environments will corrode, break down and present
potential issues with safety and electrical integrity. For these unique environments, it is recommended
to use devices that are watertight (IP66 or greater) to resist ingress of water, dust and other
contaminants. Devices should also be constructed from durable materials designed for use in harsh,
corrosive environments - like stainless steel, glass-filled nylon, nickel plated metals, etc. Further, it is
vital to protect devices wherever possible from the hazardous environments to which they are exposed
with covers, flip-lids and strain relief solutions. Replacing standard products with these devices
designed specifically for harsh environments will maximize safety, productivity and longevity.
UNDERSTANDING THE ENVIRONMENT
Arrow Hart discovered multiple opportunities to upgrade devices in the
facility. In those areas that are regularly exposed to hose down or spray with
cleaning agents, Watertight receptacles, plugs and connectors were
recommended. These will provide the water and dust protection required for
safe and dependable use even when exposed to repeated hose downs and
cleanings. In areas exposed to incidental water spray, humidity and airborne
contaminants, Arrow Hart recommended Corrosion Resistant receptacles, plugs and connectors. These
devices are constructed from special materials made for long-term use in corrosive environments.
Arrow Hart also recommended a variety of flip covers to protect receptacles
and switches throughout the facility. These common points of electrical
control and distribution can easily fall victim to corrosion and physical failure,
presenting a common safety hazard, and often requiring repeated replacement
in a Food & Beverage facility. By simply using the right kind of device and
protecting it with a cover while not in use, you can drastically extend the life of
the device and the safety of employees and equipment.
Another common point of failure with wiring devices is due to strain on cable and conductors. It is
common on plugs and connectors used in industrial applications to have the cable jacket fray or pull
away from an installed device, exposing the user to live conductors. This hazard can easily be avoided
by properly installing the device to the cable and using a Wire Mesh Grip for added strain relief. This
simple accessory is ideal for any plug or connector used as a service drop, moved frequently, or could
be pulled from the cable. Wire Mesh Grips are also ideal for cables dropping from enclosures or power
distribution points, as they service to relieve strain from these entry and exit points.
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Another recommendation was to upgrade multiple motor control switches.
In industrial manufacturing facilities, an auxiliary means of motor
disconnect is required within line-sight of the motor it controls. In Food &
Beverage facilities, these motor disconnects are typically in close
proximity to the food production line, which is often exposed to liquids,
food particles, water and cleaning agents. In the case of Crown Candy,
these motor controls were regularly exposed to sugars and syrups, which
took their toll on device integrity over time. For these applications, Arrow
Hart recommended the X-Switch™, an industrial motor control switch
designed specifically for Food & Beverage applications. The compact,
stainless steel, NEMA 4X enclosure and rugged switch design is ideal for motor control applications like
those in Crown Candy, and will provide quality, maintenance-free performance for years to come.
Further, due to its unique design, the X-Switch is certified by the National Sanitation Foundation (NSF)
for use in Food & Beverage ‘splash zone’ applications, making it an ideal ‘clean’ solution for motor
control within a food manufacturing facility.
One of the more challenging evaluations involved the facility’s
chemical waste building, which houses spent chemicals used in the
manufacturing and cleaning processes. The pumps housed in this
building required a local means of connectivity, but the receptacles
and plugs used in the past were prone to failure on a monthly basis.
For this application, Arrow Hart recommended a rugged Portable
Outlet Box with corrosion resistant receptacles and flip-lid cover
plates, which will ensure long-lasting durability in this extremely
corrosive environment.
LONG-TERM BENEFITS
Following the initial wiring devices audit and results, Arrow Hart conducted a follow-up visit with Crown
Candy to further detail the exact products and tools required to best perform the replacement of the
devices needed. All applications were documented and a detailed list of materials was created for the
recommended upgrades. Crown Candy is currently in the process of integrating all recommended
changes and products into their facility, taking advantage of equipment changeover and downtime of
specific lines. Upon full integration, Crown Candy Corporation will enjoy a variety of long-term benefits,
including increased efficiency, reduced downtime, code compliance and workplace safety.
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AUDITING CONVENIENCE
Recognizing the benefits of this and numerous other facility audits, Arrow Hart has developed a
comprehensive, easy-to-use auditing program for any industrial manufacturing environment. The
program, called SAFE Solutions, now allows Arrow Hart representatives to assist other facilities in
identifying challenges faced as a result of improper or failing wiring devices. The tools help facility
managers, engineers, and maintenance to perform wiring device audits using a convenient audit pad to
locate and recommend solutions that meet a specific facility’s needs. The program has helped facilities
to better identify and recommend extensive improvements in safety and compliance.
About Cooper Wiring Devices
Cooper Wiring Devices, a trusted name in electrical products, features Arrow Hart commercial and
industrial solutions and CORE Lighting Controls. Including such product lines as ArrowLink, RhinoBox,
Aspire, Aspire RF, and MediaSync, Cooper Wiring Devices is committed to providing products that
increase productivity, energy efficiency, safety at work and in the home, and provide reliable
performance. A division of Cooper Industries plc (NYSE: CBE), Cooper Wiring Devices is headquartered
in Peachtree City, GA with international manufacturing and distribution facilities. For more information on
Cooper Wiring Devices visit www.cooperwiringdevices.com.
About Cooper Industries
Cooper Industries plc (NYSE: CBE) is a global manufacturer with 2009 revenues of $5.1 billion.
Founded in 1833, Cooper's sustained level of success is attributable to a constant focus on
innovation, evolving business practices while maintaining the highest ethical standards, and meeting
customer needs. The Company has seven operating divisions with leading market share positions
and world-class products and brands including: Bussmann electrical and electronic fuses; CrouseHinds and CEAG explosion-proof electrical equipment; Halo and Metalux lighting fixtures; and Kyle
and McGraw-Edison power systems products. With this broad range of products, Cooper is uniquely
positioned for several long-term growth trends including the global infrastructure build-out, the need to
improve the reliability and productivity of the electric grid, the demand for higher energy-efficient
products and the need for improved electrical safety. In 2009, sixty-one percent of total sales were to
customers in the industrial and utility end-markets and thirty-nine percent of total sales were to
customers outside the United States. Cooper has manufacturing facilities in 23 countries as of 2009.
For more information, visit the website at www.cooperindustries.com.
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