Tube specialists shake up productivity with PDJ Vibro
HLP Tube Formers has introduced finishing, deburring and drying equipment from Vibro and eliminated production bottlenecks.
HLP Tube Formers has installed a PDJ Vibro EVP-RA 550 vibratory finisher and an EVK350 vibratory dryer.
Manufacturing steel tube for automotive, construction, sports and hydraulic applications, the company had encountered bottlenecks in its deburring and cleaning department which used two barrel-type machines to handle over 250,000 tubes per month.
Managing Director, Mr Garry Page comments: “We were using barrel finishing machines that were labour intensive and time consuming and loading and un-loading was painstaking. We used to put the parts into boxes that were then emptied into the barrel finisher. Once processed the parts fell from the barrel back into boxes that were then dipped into a vat of liquid inhibitor that coated the parts to prevent corrosion. Following dipping, the boxes would be left for up to an hour for the parts to drip dry. Looking back we don’t know how we managed.”
As Mr Page continues: “Before installing the EVP-RA 550 we always had a backlog in the department. Now we have replaced two machines with one finisher and it gives us a finished part quality that is consistently to a standard above that previously achieved. Not only do we have better quality but the PDJ Vibro machine is more productive and credit to the acoustic lids the machine is considerably quieter.”
The EVP-RA 550 is estimated to be at least 15 per cent more productive than the previous two machines combined, whilst being considerably quieter than its predecessors. Parts are moved directly from the EVP-RA 550 by conveyor into the EVK350 without operator intervention. Eliminating the load and unload operation from one machine to the next has improved throughput, product quality and consistency as well as reducing the labour requirement in the department.
Once parts are transferred to the EVK350 the machine removes oil and swarf remnants to completely dry the parts without having to leave the parts stand to drip dry – as was previously the case.
The EVK350 easily separates HLP’s 6mm to 65mm diameter tubes from the maize granules with its integrated ramp, leaving the parts to be caught in boxes ready for further processing operations or dispatch. The exceptional heating system in the maize dryer delivers the parts to boxes in less than 30 minutes, a processing reduction of 50 per cent compared to the previous drip dry method.
Following the immediate success of both PDJ Vibro machines, HLP Tube Formers purchased a second finishing machine in 2005 to accommodate increasing capacity levels. The third addition, an EVP-A 350 vibratory finisher has a high abrasive efficiency that delivers exceptional surface finishes to HLP Tube Formers products. With continuously adjustable vibration controls, the EVP-A 350 comfortably and rapidly processes all the parts that HLP put through the machine.
Gerry Page concludes: “It isn’t only the success of the PDJ Vibro machines that will see us do further business with the company. The PDJ Vibro staff are very knowledgeable and understand our exacting needs. If we ever have a query or a maintenance issue they are available immediately and this is priceless in our industry.”
