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New Technology Provides quick change screens product plant in Deloro Stellite
The output speed is not enough. In the processing industries where the products share production lines, the rate of change of the product can make the difference between the margins as healthy and unhealthy.
In search of higher margins, no processor can fail to provide service in exchange for excess product. Nor can they afford to work to clean and maintain surplus cumbersome machines obsolete. However, to avoid cross contamination, especially in dry bulk applications, no corners can be omitted. That's why the streamlining the production process from input to a review of the final product can be critical.
When a coating process to avoid a production bottleneck by upgrading to a new screen technology, saw him accelerate the shift of product, with the addition of fast refund to the baseline.
"We reduced downtime switching in the third and improved product quality over the Russell Finex Sieves compact, "says Bob Minton, manager of maintenance at the Deloro Stellite coatings operations in Goshen, Indiana." By speeding up the cleaning, prevention cross-contamination and help the quality of the product, we achieved return on investment in compact screens in a few months. "
A Need for Speed
Deloro Stellite is a global provider of solutions to industrial wear problems, where heat, corrosion and abrasion may limit life components. Produces proprietary metal alloys from cobalt and nickel, which have adequate physical and metallurgical properties to the industrial challenges to wear.
In coating operations, screening is a critical process, since the size of metal powders controls its flow at points of welding customers in a range of applications. To streamline production and improve quality, the company planned to add new screens for all initial inputs and final products powder powder in Goshen, Indiana plant.
While the company used traditional sieves smaller volume powder classification, traditional sieves were felt Minton too slow and complex for the current needs of Deloro Stellite.
"With 5,000 product variations, we would have to disassemble each sieve, cleaning and assembly 10-12 times a day, "says Minton." We needed screens that were easier to use than the same type of age who has been on the market for 40 years. "
The traditional sieves were cumbersome to work, stripped, cleaned and put back together. And if the seals were not aligned correctly, that could leak, which could ruin a lot of products.
"Band clamps carried out, bent, is broke or cracked, and the seal had to align all the way around the flange, "says Minton." It took two people to the work of seal around large units in diameter, with no alignment pins or guides. "
Fine dust sometimes found its way into the threaded clamping bolt on these screens also traditional. When this happened, called sieve food operators have the pin cut and replaced with a new one. Maintenance is also increasingly called that the vibrations necessary adjustmenting sieves. All this added to the shutdowns.
In a show in bulk powder processing traditional provider promised to show a montage screen "shortcut" but was unable to put the unit back together. Minton decided it had had enough traditional screens, so they began searching for low maintenance units in an effort to streamline the production process while reducing man-hours.
Speed Delivered
In search of a solution, Minton returned to a state of the art of Russell SieveÒ Covenant Finex. The unity of design and ease of use impressed Minton, who felt that accelerate the product change and improves the bulk powder processing. Participation a test proved him correct, and now there are four screens in the plant compact Goshen.
"An operator can disassemble and assemble the screens in less than one minute without tools, "says Minton." Just undo the four catches with hand, lift the top cover and lift the screen out. To install, reverse the process. It is sealed to perfection. Because the screen drops into a hole, there is no possibility of misalignment, and cleanup is easy with a vacuum line. "
"Everything is right there, easy access," says Minton. "Pop a cap on the end of the motor and no vibration adjustments. It's so easy to make adjustments to one of our junior engineers re-aligned process. We show you once, and was comfortable enough to make the same adjustment. "
Minton estimates the new screens save about an hour a day in production time compared to the process of introducing cumbersome product required by traditional screens. product output and quality are also improved by the new screens Russell.
Designs incorporate traditional spring-mounted base and a custom motor with a pair of eccentric weights at the end of the motor shaft. However, this design lacks precision in controlling the strength of the vibration imparted to the mesh, and is usually limited to a speed of 1200 rpm.
On the contrary, the Covenant SievesÒ Russell Finex omit the need for springs and instead uses a patented rubber suspension. Combined with its high speed of 1800 rpm engine vibration and easy adjustable weight system allows much higher forces being transferred through the mesh itself. This creates a more refined and vigorous action, significantly raising screening efficiency.
"The adjustable weight system makes it easy to set up the machines," says Minton. "It helps us get the right time on the screens to get every bit of dust as possible, minimizing the loss of large-size product. "
The design of these screens can be further step to increase system performance by Russell VibrasonicÒ deblinding in relation to the screen. For the activation of the wires mesh screen with an ultrasonic vibration, friction between the product and the screen is effectively removed. In the case of Russell Finex machines, mesh "Blinding" is eliminated, which helps move material through the screens faster.
From the crack Sievesare Covenant entirely free and polished stainless steel construction including the current, all surfaces are easy to clean.
"The screens are compact it easy for our operators to rapidly and completely clean product changeover without tools, "says Minton." Help with the production, product purity and product loss. Saving even a batch of possible cross-contamination could pay for the cost of the screens. "
"With the new screens, our customers get a better product and better delivery capability in the long term," concludes Minton.
Russell Finex has over 75 years of experience in manufacturing and supplying separators, sieves and filters to improve productivity and ensure product quality. The company offers a wide variety of industries in over 100 countries with applications including adhesives, ceramics, chemicals, colors, enamels, explosives, food, inks, latex, metal powders, paint, paper coatings, pharmaceuticals, plastisols, powder coating, and waste oils.
About the Author
Russell Finex assure and enhance the reputation of companies in almost every process industry throughout the world. We achieve this by manufacturing and supplying sieves and filters to improve your product quality and ensure your powders and liquids are free from contamination.
Russell Finex Ltd, Russell House, Browells Lane, Feltham, Middlesex, TW13 7EW, England,
Tel.: +44 (0)208 818 2058,
Fax.: +44 (0)208 818 2060,
Email: enquiries@russellfinex.com
www.russellfinex.com
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