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Material Handling Case Study

Application Overview:

Extruder uses 50-3 attachment chains, running in parallel, for window frames.


Problem:

The extruder kept malfunctioning, as the 50-3 attachment chains did not run in parallel correctly.


Solution:

50-3 attachment chain pre-loaded and matched and tagged to a Class 2 standard Baked on DF coating applied to pins and bushings, improving wear performance


Cost Savings

Under review


Prevented Stiff Joints and Increased Wear Life by 7%

Application Overview: Chain conveys ceiling tiles through a drying oven.


Problem:

The high temperatures stiffened the chain joints. The customer purchased chains from various manufacturers, with no improvement in stiffening of joints.


Solution:

80 chain with 80 sidebars, 80H roller links, and 80H pins. Unique chain design increases lateral clearance between sidebars by a factor of 2, preventing stiff joints. Design increases bearing area by 7%, which increases wear life by 7%


Cost Savings"

Under review


Better Resistance to Shock Loads

Application Overview:

Wallboard Kiln Dryer


Problem:

The high temperatures caused stiff joints, and the chain wore out after 7 years. Also, shock loads were causing pin failures.


Solution:

81XKD chain, designed with special clearances for Kiln Dryer applications

Special clearances help prevent stiff joints

Through hardened pins raise resistance to shock loads


Cost Savings

Under review


Chain Lasted 3X Longer

Application Overview: C2060H chain conveying concrete bricks from cutter to stacker.


Problem:

The imported chain had problems with excessive sidebar wear and elongation.


Solution:

Imported chain replaced with standard C2060H

Chain’s usage time 3X longer


Cost Savings"

Savings from downtime: About $1,500


Prevented Product Contamination

Application Overview:

A polycarbonate resin thermoplastic sheet manufacturing facility.


Problem:

The lubricant on overhead chains carbonized due to heat. The carbonized lubricant then fell into uncured sheet coating, causing the entire sheet to be rejected.


Solution:

Chain with Extended Life CHP Series hard chrome plated pins, giving the pins an extremely hard wear resistant pin surface

Chain’s life increased 3X


Cost Savings

$30,000 labor savings with prevented breakdown

PM based on $40,000 average in past years


Eliminate Unnecessary Replacements

Application Overview: 60-2 roller chain conveys wooden kitchen and commercial cabinets through a paint booth, allowing precise spraying time for stains and finishes.


Problem:

Chain elongation prevented precise sprayer timing settings after only 2 years usage.


Solution:

60-2 roller chain was replaced with 60-2 Extended Life CHP

Better wear resistance

Frequency of timing adjustments reduced

Life of chain increased to 6 years


Cost Savings"

$13,820 initially

$2,303 annually


Cut-to-Length Service

Application Overview:

A lathe operation that utilizes more than 10 feet of 100-6 riveted roller chain.


Problem:

2 boxes of chain needed to be purchased. The leftover chain needed to be inventoried, and the chain assembly required spot welding the connecting link to the pin.


Solution:

“Cut-to-length” chain assembly

Press fit connecting link provided, increasing the chain life with good pin-to-link retention


Cost Savings

$1,941


Extruder Chain Successful Over Extreme Conditions

Application Overview: Concrete roofing tiles manufacturer. 40-2 chain used on an extruder drive.


Problem:

The chain was not lubricated, and was subject to heavy loads in an area with high contamination levels. The chain’s life was only 1-½ weeks.


Solution:

40-2 CHP (Hard Chrome Pin) extruder drive chain

2-year chain life


Cost Savings"

$42,700 annually

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