The Critical Role of the Auxiliary Drive in Spiral Freezers – When to Replace & Why It Matters

Welcome to the fifth instalment of our “Critical Spare Parts” series, where we break down the components that keep your spiral freezer running smoothly.
When it comes to spiral freezers, every moving part plays a critical role in ensuring products are frozen consistently and reliably. One component that often stays hidden in plain sight is the auxiliary drive, also known as the take-up drive or tension drive. 

While it may seem minor compared to the main drive, when this part fails, the production stops. In this article, we’ll walk you through what the auxiliary drive does, why it matters, when you should replace it, and how ignoring it once led to major trouble for a ready meals’ producer — and how Korutek stepped in to fix it. 

What Does an Auxiliary Drive Do? 

The auxiliary drive’s main job is to keep the spiral belt properly aligned and tensioned. Think of it like the helping hands for the main gearbox, making sure everything stays smooth and steady as your products travel through the freezing process. 

If the tension isn’t right: 

• The belt can slip out of place. 

• Products can get jammed inside the spiral. 

• Freezing becomes uneven. 

• There’s a risk of product damage and waste. 

Just like a car needs the right tire pressure to run safely, your spiral freezer needs correct belt tension to operate efficiently. 

Why Is the Auxiliary Drive So Important? 

It’s easy to neglect the auxiliary drive because it doesn’t scream for attention—until something goes wrong. Without correct tension, the belt can surge, slip, or misalign, causing production chaos. 

Here’s what could happen if it’s not working properly: 

• Product misalignment: Frozen products coming out unevenly stacked or damaged. 

• System downtime: Emergency stops to untangle jams. 

• Increased maintenance costs: Belt wear and tear increase. 

When Should You Replace the Auxiliary Drive? 

Based on industry best practices, we recommend replacing the auxiliary drive every 5 years, or sooner if you notice any performance issues. 

Some signs to know it’s time for a replacement: 

• The belt feels loose or surges during operation. 

• Frequent product jams. 

• Unusual noises from the drive area. 

• Difficulty maintaining belt alignment. 

It’s better to plan replacements proactively during a scheduled shutdown rather than waiting for an emergency. 

A Real-Life Example: How a Faulty Tension Drive Crippled a Ready Meals Producer 

One of our clients, a major ready meals manufacturer, faced persistent issues with their spiral freezer: belt surging, frequent jams, and inconsistent freezing.  

Their spiral freezer suddenly experienced a belt jam during peak production. Costly food products, worth a significant sum, were lost, and the factory floor turned into a chaotic cleanup of jammed items. 

After the investigation, it was clear — the auxiliary drive had failed. The belt had slipped out of alignment, causing a domino effect across the production line. Multiple technicians had inspected the system, but no one could pinpoint the problem. 

When Korutek’s engineers stepped in, we discovered something everyone else missed: The take-up drive was wired incorrectly, causing excessive amperage and motor overheating. This misconfiguration had been straining the system for months, leading to premature wear and erratic belt behaviour.

Our team rewired the drive, recalibrated the tension, and provided a replacement unit with specialised low-temperature coating to prevent future issues and extend the lifespan of the auxiliary drive.  

The result? Smoother operation, reduced energy consumption, and no more unexpected shutdowns. 

What sets us apart is the Attention to detail. While others focused on superficial fixes, we dug deeper to find the root cause, saving our customers from recurring headaches. 

Key Reasons to Replace Your Auxiliary Drive on Time 

• Avoid emergency downtime: Planned maintenance costs far less than unexpected breakdowns. 

• Protect product quality: Consistent belt tension means consistent freezing and ensures hygiene. 

• Extend equipment life: Reduces unnecessary strain on the spiral system. 

• Enhance safety: Avoids accidents due to belt surges or jams. 

Proactive Maintenance Tips 

Here’s how you can stay ahead: 

• Regularly inspect belt tension and drive performance. 

• Schedule a full inspection of critical drive components every year. 

• Replace tension drives every 5 years — don’t wait for visible damage. 

• Keep spare parts like tension drives in inventory for fast replacement. 

How Korutek Supports Your Operations 

At Korutek, we believe in proactive partnership.

We work closely with customers to plan critical part replacements during convenient windows, avoiding surprises later. Our engineers also provide full machine inspections to catch and resolve small issues before they become big problems. 

Think of us as your co-pilot, helping steer your production smoothly, safely, and efficiently. 

Conclusion 

The auxiliary (take-up/ tension) drive might be small, but it’s mighty in how it protects your spiral freezer’s performance.
Ignoring it could mean sudden breakdowns, lost products, and costly repairs — but with regular checks, timely replacements, and the right support, you can keep operations running like clockwork. 

If you’re unsure when your tension drive was last inspected, maybe it’s time we had a chat.