Warehouse and distribution center managers often focus on moving boxes, but the key to protecting a valuable fleet of material handling equipment lies in managing the dust and grime that accumulates around it.
While preventive maintenance programs typically emphasize lubrication, inspections, and parts replacement, industry experts are increasingly highlighting the critical—and often underestimated—role of routine cleaning in extending the lifespan of forklifts, conveyors, and automated storage systems .
“It’s a simple upgrade that delivers big results in uptime, compliance, and peace of mind,” said Mitch Hayes, President of Kardex Solutions–North America, when discussing the company’s new cleaning robot for automated storage systems .
The Hidden Costs of Grime
For material handling equipment, dirt is more than just an aesthetic issue. Dust, debris, and grime accumulate on moving parts, electrical contacts, and hydraulic systems, acting as an abrasive that accelerates mechanical wear and leads to overheating .
In food processing and other industries with strict hygiene standards, cleaning is a critical component of operations. One equipment manufacturer notes that “sanitation is a critical aspect of any food-manufacturing operation,” and has designed specialized tilters to make cleaning carts and bins easier and safer .
When debris accumulates, it increases resistance on components, straining engines and motors. Over time, this strain causes parts to fail prematurely. The challenge is particularly acute in industries dealing with highly abrasive materials. In a case study at a steel plant, insufficient belt cleaning led to carryback and spillage that “fouled rolling components leading to premature equipment replacement” .
Cleaning vs. Repair
One cleaning equipment supplier states that with proper care, heavy-duty cleaning equipment typically lasts between 5 and 10 years. However, harsh industrial conditions can significantly shorten that lifespan . The reason is simple: routine cleaning helps prevent small problems from becoming large, expensive failures.
“Debris and grime can accumulate, increasing resistance and strain on the parts. When you clean a machine, you remove any debris that could interfere with its operation, allowing it to maintain peak efficiency,” according to one industry analysis .
The financial impact is measurable. When carryback and spillage are not managed, manual cleanup, product loss, and excessive maintenance raise the cost of operation. In contrast, effective cleaning programs can nearly eliminate these issues .
Best Practices for Cleaning
Implementing a cleaning routine is not a one-size-fits-all solution. Experts recommend several key practices for effective equipment maintenance:
-
Set a Schedule: Manufacturers typically recommend specific cleaning intervals. For some equipment, this may be as often as every 50 hours of operation .
-
Clean Before Lubricating: Greasing dirty equipment can trap debris, causing more damage than it prevents. Always clean components thoroughly before applying new grease .
-
Use the Right Tools: Avoid aggressive cleaning agents and never use high-pressure cleaning equipment on electrical components, bearings, or plastic parts .
-
Focus on Critical Zones: Hydraulic systems, electrical contacts, and air filters are common failure points that benefit significantly from regular cleaning .
The Impact on Automated Systems
The rise of automated storage and retrieval systems (AS/RS) has made cleaning more complex but no less important. Dust and debris can accumulate on the grids where robots operate, potentially leading to erratic performance or complete failure.
As robotic systems become more common in warehouses, tools like automated vacuum cleaners are emerging to help maintain grid hygiene without interrupting operations . This investment in cleanliness directly protects the lifespan of expensive automation equipment.
Ultimately, routine facility cleaning is an investment in the longevity of the equipment. It reduces friction, prevents overheating, and, by removing abrasive materials, ensures that parts last as long as intended. For facility managers, a regular cleaning regimen may be the most cost-effective step they can take to protect their operation’s most important assets.
