Case Study: Enhancing Carbon Extrusion Efficiency

The Problem

A global manufacturer of graphite and carbon products encountered a significant issue with their Carbon Extrusion. The problem centered around the cooling of material during the extrusion process, which led to production inefficiencies, an increased rate of scrapped material, and consequent machine downtime for each cycle of the press.

The Solution

Understanding the impact of this issue on productivity and operational costs, the Ajax/CECO/Erie Press team devised a solution to counter the challenge. The approach involved a retrofit addition of a Heated Plunger Head/Vacuum Break to the Carbon Extrusion Press.

After a thorough on-site inspection and measurements, the team designed and created a new plunger head for the machine. This addition featured an internal pathway allowing for the circulation of heated oil or water, which kept the plunger head heated during the extrusion process. This innovation aimed to eliminate the unwanted cooling of the material, thereby enhancing the efficiency and efficacy of the extrusion process.

The Outcome

The implementation of the heated plunger head proved successful, substantially reducing machine downtime and the production of cooled material after each refilling. The project cost was approximately $400,000, a worthy investment considering the savings from the reduction of scrapped material and downtime for each cycle of the press.

The new heated plunger head system helped to maintain a consistent and optimal operating temperature, thereby streamlining the extrusion process and improving overall productivity. Consequently, the customer experienced enhanced operational efficiency and cost savings.

The Ajax/CECO/Erie Press Advantage

The success of this project underscores the unique strengths of the Ajax/CECO/Erie Press team. We are dedicated to understanding our clients’ unique operational challenges and delivering tailored, innovative, and cost-effective solutions.

In this case, our ability to identify the underlying issue and devise a creative and effective solution resulted in significant operational improvements. Our commitment to innovation, efficiency, and customer satisfaction is reflected in our ability to deliver high-quality, robust solutions that provide lasting value to our customers.

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