Case History: On-Site/Portable Machining Saves Small Fortune For Paper Mill

 

de-barker machine

 

A paper mill in upstate NY has a very large machine that removes bark from logs. This is an initial phase in the papermaking process where raw logs go in one end of the process and finished paper goes out the other. ….Remarkably, this machine is called a de-barker.

The de-barker has 3 large rotating shafts that are timed together with sprockets and chains.

Unfortunately, the sprockets & bushings had spun on one of the shafts. The original sprocket mounting was a B-Lock keyless bushing design.  It was determined that a direct keyed, interference fit sprocket mounting design would be more durable. However, to disassemble the de-barker, remove the large shaft and ship it to a qualified machine shop was definitely cost prohibitive.

The mill was desperate for an alternative solution. They found us online when searching for a company who had On-Site/Portable Machining capabilities.

Knowing their desperate situation, we responded almost immediately. Once on site, we first machined the shaft in-place to remove the scoring damage caused by the spun bushing. The shaft was originally 8” diameter. We machined it to a clean 7-7/8” diameter. This was accomplished with our portable lathe that mounts to and swings about the axis of the stationary shaft. Following the machining of the damaged shaft, we mounted a portable key mill onto the shaft and cut two keyways: 2” wide x 5/8” deep x 8” long. Keyway alignment was critical to maintain the appropriate sprocket position. The new sprockets were then machined to accommodate the required shrink fit onto the newly machined shaft.

The entire machining and re-assembly process was accomplished in one weekend, allowing the de-barker to go back into operation on Monday morning, definitely ahead of schedule.

The savings realized by eliminating the de-barker disassembly and associated downtime is likely in the seven figure range.

 

On-Site/Portable Machining is a dream come true. It can eliminate very costly machine disassembly.

 

Our many portable machining capabilities include:

Flange Facing

machining flanges

  • Machining full face, raised face, back face and grooved flanges; internal and external mounted machines available; to 120″ O.D.
  • Applications include cutting ‘O’ Ring grooves, vertical grooves, V grooves, pipelines and reactor vessel flanges.

Pipe Cutting / Weld Preparation

cutting pipe

  • Applications include all types of vessels, pipes, valves and tubes.

Shaft & Journal Machining

shaft and journal machining

  • Repair of worn or damaged shafts and journals up to 11″ in diameter, including stepped profiles, ring grooves and parallel shafts; weld build-up if necessary; polishing available.
  • Applications include mixer journals, roll journals, alternator and ventilator shafts, crank pins, presses, turbine rotor journals, fan shafts and pumps, and more. 

Line Boring

line boring

  • Sizes include 1- 36″ in diameter and in excess of 60″; to 12′ distance between bores. Inquire about larger bores and the alignment that is always necessary to ensure accuracy.
  • Applications include industrial equipment and machinery including mining & earth- moving equipment, excavator buckets, printing presses, pump housings, valve bodies, valve seats, turbine casings, diesel engines, crank and cam shaft housings.

Milling

milling plates

  • Applications include milling and fly-cutting pump and motor bedplates, milling heat exchanger division plates, external and internal keyways in shafts and bores, crane pedestals and tracks, bedplates, steel rolling mills, hatch covers and square flange machining, blast and oxygen furnaces, concast units, sinter plants, iron ore terminals and mill stands, joint faces on fin/fan coolers and intercoolers.

Contact us today to speak with our staff! We service a large number of industries including emergency repairs and routine maintenance services!

Keep your Plant Up and Running.

What You Need to Know About Sanitary Piping Design

Marshall Industrial Technologies provides a full range of capital project and plant maintenance services. Our offerings include initial construction and installation as well as maintenance routines that can keep your facilities running smoothly.

 

We particularly specialize in process piping system design, fabrication, installation and maintenance. We can fabricate and install austenitic sanitary and high-purity process piping systems in a wide variety of facilities using Orbital and manual TIG welding techniques.

 

We offer complete sanitary piping services for new construction, modification, and expansion of piping systems. In this way, we’ve perfected ways to install hygienic piping systems in a variety of facilities, including those in the food and beverage, cosmetics and pharmaceutical manufacturing fields.

 

What Is Sanitary Process Piping?

Sanitary process piping systems handle food, dairy, and pharmaceutical processes. Because these products directly affect customers’ health, they need to be assembled with strict adherence to industry and third-party regulations.

One of the most important ways to preserve hygienic processes is through the installation of sanitary process piping for your facility’s fluids. Sanitary process piping manages the movement of fluids throughout a production facility. A few traits that all systems have in common include:

 

  • They meet higher cleanliness standards than regular piping systems.
  • They’re installed using orbital or manual TIG welding processes.
  • Their surfaces are easier to clean and sterilize than those of other piping systems, which helps ensure product integrity.

These traits are inextricably interlinked. Using orbital or TIG welding processes to build your plant’s process piping system produces flawless internal and external weld contour making them easier to clean and sterilize, which in turn meets industry sanitary and high purity piping standards.

 

Orbital welding is an automated welding process that results in smooth internal surfaces for the pipe welds. This sets it apart from manual welding, which can leave bumpy or crevice-filled interior joints that collect materials and encourage the growth of bacteria. Orbital welding creates a uniform weld bead that fully penetrates the pipe joint thereby producing superior weld quality, thus enabling pipe interiors to reach low bacterial levels faster and stay safer over time.

 

The Importance of Industry Standards

Before your plant or processing facility can produce pharmaceutical or food/beverage products, it must meet the FDA’s strict process validation standards. For this reason, it’s usually easier to work with one vendor throughout the entire piping installation process, because doing so involves fewer communication breakdowns that might otherwise result in regulatory penalties.

 

Process piping systems in a wide variety of industries must accord to the following industry standards:

 

  • 3-A Sanitary Standards
  • FDA (Food & Drug Administration), CFR (Code of Federal Regulations), and CGMP (Current Good Manufacturing Practices) standards
  • ASME Bioprocessing Equipment Standard (BPE-97)
  • AWS (American Welding Society) D18.1/D18.2

Is Sanitary Piping the Same as Sewage and Sewer Piping?

Sanitary piping actually refers to two different types of piping systems in the United States. Although the name applies to the high-purity process piping for food, dairy, and biopharmaceutical manufacturing, it also can refer to sewage piping, which carries potable water and wastewater to and from buildings. Since both of these systems involve the movement of fluids while maintaining high standards of safety and interior integrity, they’ve traditionally fallen under the same umbrella.

 

That being said, many other English-speaking countries differentiate between the two systems. In the U.K., for example, the phrase “sanitary piping” only describes water and sewage piping systems, whereas process piping that handles food and pharmaceutical applications is referred to as a hygienic piping system.

 

What Can Marshall Industrial Technologies Do for You?

Reliable sanitary process piping systems are absolutely essential for your processing plant. At Marshall Industrial Technologies, we assign one project manager to every client to oversee your facility’s pipe design and installation from start to finish. This facilitates more customer success as the project manager becomes well acquainted with your facility’s requirements over the course of working with you.

Contact our team here to learn more about our process piping installation services, or request a quote to find out how you can get started.

 

5 Easy and Essential Tips for Industrial Equipment Maintenance

Marshall Industrial Technologies provides a wide variety of maintenance services on either a temporary or ongoing basis for industrial facilities. Whether you need routine maintenance, preventative service, or an emergency fix, we’re here to help.

We assist many different industries, as well as the local, state, and federal government, maintain their:

 

  • Mechanical systems
  • Electrical systems
  • Process piping systems
  • HVAC-R systems

With our wealth of experience, we’d like to offer you some essential tips for maintaining your industrial equipment.

 

What Are Some Basic Tips for Industrial Equipment Maintenance?

In order to keep your operation running smoothly, all of your equipment must be in good working order. Here are some steps that you can take to ensure that your equipment stays functioning:

 

  1. Check all machinery carefully for signs of wear and tear. If your equipment is in heavy use, it will wear out over time, creating high amounts of stress on the rest of your system. For example, a misaligned gear or belt in your machinery can lead to excessive vibration, which can have a cascading effect that further damages your equipment. Belts warp with time, seals can dry out and crack, and bolts will loosen and shear—all of which makes it essential to carefully monitor your equipment for signs of wear.
  2. Lubricate all machines as required, and check lubricationlevels often. Lubrication prevents water corrosion and keeps all the parts in your equipment moving efficiently. Engines, power trains, and hydraulic lifts all require lubrication to function.
  3. Make sure you regularly clean your machinery and equipment, especially seals and filters. Excess levels of dirt and debris will damage your components by grinding down sensitive equipment and clogging fans and other ventilation systems. Moisture in unsealed environments destroys electronic systems and compromises machine functionality.
  4. Keep up-to-date records of all maintenance and operational training performed on your equipment to ensure that regular maintenance is carried out. Having a complete log of your machinery’s maintenance and repair schedules will help you better diagnose problems in case of malfunction and allow you to anticipate future repairs. Record keeping should extend to your employees, as well. Keeping maintenance personnel on a regular training schedule will help them stay abreast of any machinery updates or best practices as they’re developed.
  5. Contact Marshall Industrial Technologies for all of your machinery maintenance needs! Many companies have found that sourcing their maintenance to qualified experts helps save them time and allocate more resources to R&D and branding. We bring an in-depth understanding of many types of industrial equipment to all our jobs, which allows us to provide top-notch service to a wide variety of industries. Our technicians are ready to perform both routine preventative maintenance and emergency repairs as needed.

The Importance of Preventative Maintenance

Just like when you go in for a routine physical, performing regular preventative maintenance will help preserve your equipment’s health. Marshall Industrial Technologies offers a wide range of preventative maintenance and repair services for clients across many industries. Our service offerings include:

 

  • Inspection and Troubleshooting
  • Diagnostic Tests
  • Servicing
  • Replacement of worn parts
  • Repairs and machine overhauls
  • Equipment adjustment and calibration

If you would like to learn more about our maintenance and repair services or wish to schedule an evaluation, contact Marshall Industrial Technologies today.

The Types of Machinery Troubleshooting You Need to Prevent or Predict Issues

Machinery failures can be a major loss of productivity for manufacturing companies. But, preventative maintenance helps to avoid such losses. At Marshall, we believe that anticipating costly failures and malfunctions is part of maintaining machinery, so we offer a wide range of industrial machinery preventive and predictive services. We’ll help your company take a more proactive approach to equipment maintenance––keeping your machinery in proper operating condition, thereby reducing the potential for costly downtime.

Services Provided by Marshall

The industrial machinery preventive/predictive services we offer include:

  • Machinery Evaluations and Troubleshooting
  • Ultrasonic Thickness Testing (UT)
    • A method for determining the working age and status of a part by measuring the thickness and corrosion of a material.
  • Hydrostatic Testing
    • A method for testing for leaks or other flaws in pressure vessels.
  • Dye Penetrant Testing
    • The application of a dye to a material’s surface to detect cracks, fractures, porosity, or leaks.
  • Machinery Alignment
    • Available for the chemical, food and beverage, pulp and paper, petroleum, pharmaceutical, printing and publishing, recycling, and rubber industries.
  • Laser Shaft Alignment
    • The use of a laser to align two or more rotating shafts in a machine.
  • Overhead Crane Installation, Inspection, Load Testing, and Repair
  • Infrared surveys
    • Infrared surveys identify “hot spots” in electrical components before they can cause system failure, or worse yet, fire damage.
  • Spare parts manufacturing
    • Our shop has the capabilities for fabricating and machining spare parts for critical components prone to failure often in a fraction of the time, and at a fraction of the cost, offered by the equipment manufacturer. This way, your plant can be prepared with back-up parts in advance to prevent unexpected downtime due to component failure.

If you’re looking for a trusted provider of industrial machinery services to extend the life of your equipment and adopt a preventative maintenance schedule, contact Marshall.

Learn more about our manufacturing equipment preventive and predictive services online at www.marshallindtech.com

 

infographic about troubleshooting industrial equipment

Piping Material for Sanitary and High-Purity Process Piping Systems

Process piping systems play a critical role in a wide range of applications and industries, including petroleum refineries, chemical, pharmaceutical, food, textile, paper, semiconductor, and cryogenic processing plants.

To meet the varying needs of these industries, Marshall Industrial Technologies tailors piping systems to each client’s specific requirements, and can assist in all aspects of design, fabrication, and installation.

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ASME Qualified Orbital Welding & Manual TIG Welding Services

A full-service, multi-skilled industrial service company, Marshall Industrial Technologies serves as a single source for routine and emergency equipment installation, machinery repair, and plant maintenance. We’re also proud to offer state of the art Orbital Welding Services.

Orbital welding involves the continuous mechanical rotation of the welding arc around a static workpiece. The process serves as an ideal solution for the welding of items that are fairly resistant to manual welding due to their shape or size.

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