Stealing back profi ts with aluminium

Lightweight, high-strength aluminium is as strong as steel and only 40% of the weight, providing a power-to-weight ratio that increases safety, productivity and ROI

By Heather Harding*

To minimise profit-stealing downtime, plant managers need reliable, efficient maintenance methods that get production back up and running quickly. This requires the right equipment – made from the best materials.

Bricking machines, suspended platforms and kiln access ramps safely speed up the refractory installation process, saving thousands of dollars in lost revenue. These useful tools are available from equipment manufacturers but can also be engineered in-house. Small differences in construction and materials can add up, though, so it’s important to thoroughly consider all options.

For many cement and lime producers, using their in-house engineers to construct kiln maintenance equipment made from steel is the go-to material because it is readily available.

However, there are more efficient materials.

Lightweight, high-strength aluminium, for example, isn’t typically used by inhouse engineers, but offers productivity and safety benefits that make it an ideal choice for kiln maintenance equipment construction. This material is as strong as steel and only 40% of the weight, providing a power-to-weight ratio that increases safety, productivity and ROI.

Partnering with an equipment manufacturer that uses high-strength aircraft-grade 6061-T6 aluminium can be the best choice for a facility’s bottom line and efficiency. Here’s how.

With every minute of downtime leading to a loss in revenue, the performance of a bricking machine or kiln access ramp during refractory installation is a manager’s top concern. Setup and teardown times are equally important when it comes to overall productivity. Getting crews in and out faster requires a machine that is just as easy to put together as it is to remove once the job is done. Much of this comes down to construction materials: heavier materials – like steel – simply take more time and energy to erect.

For example, a steel kiln access ramp can take a full crew six to 12 hours to assemble, increasing downtime both before and after maintenance and negatively impacting cost efficiency. The weight of the steel components also requires the use of heavy-duty equipment and complex hoists and rigging methods, increasing cost and risk of injury.

A similar ramp manufactured with lightweight, heavy-duty aluminium can be assembled in as little as 1.5 hours –depending on burn floor configuration – with a small crew and only light equipment, such as a forklift. Maintenance equipment that employs a modular design can further increase installation efficiency.

With equal strength and signifi cantly less weight, equipment manufactured with aircraft grade aluminium offers some of the highest load capacities on the market These lightweight components can be transported into the kiln by just one or two people and can be quickly erected using pin connections, rather than nuts and bolts. By eliminating the need for extra equipment and manpower in the assembly process, aluminium ramps, bricking machines and platforms increase productivity and safety while reducing overall costs with every setup and teardown.

In addition to faster setup, plants will see increased durability from high-strength aluminium kiln maintenance equipment. With equal strength and signifi cantly less weight, equipment manufactured with aircraft grade aluminium offers some of the highest load capacities on the market. Some custom-made bricking machines can hold as much as 6,000 kg (13,200 pounds) with an optional capacity upgrade, allowing them to easily handle three full pallets of brick.

This is up to twice the capacity of the alternative steel machines – maximizing productivity without risking safety.

Industry-leading specialty manufacturers who incorporate high-strength aluminium into their kiln maintenance support equipment designs do so because of its increased load capacity over other metals. These companies use certifi ed engineers and aluminium welders to ensure their products address the unique needs of each kiln site.

The products are manufactured to international safety standards and are subjected to rigorous safety tests to ensure the materials and designs won’t falter even when working at capacity.

The result? Custom engineered bricking machines with a 3-to-1 safety factor. Crews with that kind of assurance can work with confi dence knowing their bricking machine, kiln access ramp or work platform can comfortably handle heavy loads.

When it comes to increasing effi ciency during refractory installation – and in other areas of kiln maintenance – strong, lightweight aluminium equipment is an easy decision for plants looking to minimise downtime and get processing back on track. �

Pressta Eisele is the number one supplier of high speed and precision saws for the aluminum industry worldwide. We manufacture from simple single station saws to fully automatic cutting lines with loading magazines and handling stations anything a modern production needs to keep up with the steadily increasing market demands.

www.pressta-eisele.de