As capital investments become slightly more risky, manufacturers can exercise caution in their operations no matter what industry they’re in by switching focus from replacements and upgrades to repair and refurbishment, especially when it comes to rotary drum maintenance.
A slowdown in manufacturing was a contributing factor in the Federal Reserve’s decision to cut interest rates by a quarter-percentage point for the first time in more than a decade. The slump, typically an indicator of wider economic trends, comes amidst the ongoing trade war that has shaken up global markets.
Some economists expect growth to pick up later this year, but the uncertainty has left manufacturers looking for ways to weather the storm. And while it might be tempting to invest in new equipment or technology, one of the best ways to stave off economic troubles during uncertain times, is to instead invest in existing plant infrastructure.
Why Focus on Existing Infrastructure?
Improving existing infrastructure through repair and refurbishment accomplishes two key objectives that can maintain a reliable and efficient operation when budgets are tight:
- It provides a level of insurance against catastrophic breakdowns
- It plugs leaking efficiencies to contribute to the bottom line
The FEECO Customer Service Team, which services industries from fertilizer production and mineral processing, to chemical production and waste recovery, has seen an increase in repair work already.
“We always recommend preventative maintenance as a best practice for rotary equipment,” says Craig Peppin, FEECO Customer Service Manager, “but it is even more critical when there is an anticipated industry slowdown and there is a need for existing operations to be more reliable.” Peppin notes that problems in rotary drums have the potential to become catastrophic quickly if not treated, so keeping up on preventative maintenance and routine repairs helps to avoid unplanned outages during a time when budgets are already stretched. “In essence, being proactive in slow times sets the facility up in the best way possible to avoid unnecessary maintenance costs and lost production time,” he says.
Apart from being a smart investment, repairing and maintaining infrastructure is also much more easily carried out during slow times, because the production schedule is more flexible.
Top Rotary Drum Maintenance Services
While all rotary drum services provide value, services focused on optimizing efficiency, prolonging equipment lifespan, and avoiding premature failures are most important in uncertain times. These services are also ideal during a slowdown, as they offer potentially significant paybacks through minimal investment. The most effective rotary drum services during an economic downturn include:
Equipment Audits
Equipment audits are the first step in any good maintenance program, identifying problems so they can be addressed before they have a chance to escalate.
In addition to identifying mechanical issues, Customer Service Engineers also often uncover ways to improve the efficiency of the unit during inspections.
Equipment audits vary depending on the type of rotary drum (dryer, granulator, kiln, etc.), but generally focus on the mechanical stability and overall condition of the unit.
Tire Grinding
Tire grinding is the process of reconditioning load-bearing surfaces by grinding in order to ensure even weight distribution across load points.
Worn load-bearing surfaces such as tires and trunnions may seem inconsequential, but actually have a substantial impact on the mechanical stability of the drum and its many components.
Alignment
Rotary drum misalignment has similar ramifications to those of worn load-bearing surfaces; the drum does not rest evenly as intended, causing stress on all components. This stress exacerbates damage over time as the misalignment progresses.
Misalignment can be corrected either manually, or with the assistance of a laser alignment tool, which provides a faster, more precise alignment option. It’s important to note that a rotary drum realignment should always be performed after tire or trunnion grinding.
Refurbishing the Internals
Internal components such as bed disturbers and flights (material lifters) are often a significant contributor to overall process efficiency and product quality. Since they are in constant, direct contact with the material running through the drum, wear is more common with these elements (though solid design and fabrication can help to stave off wear).
A slow period is an optimal time to assess the drum internals and make any necessary repairs. This may help to improve product quality, reduce fuel costs, and increase efficiency, quickly recuperating the investment.
Process Optimization
Though not necessarily a form of preventative maintenance, process optimization can offer savings when looking to change the parameters of an operation.
In some cases, existing equipment, such as a rotary kiln, can be reconfigured for use in a new process, avoiding the capital expense of a new unit.
This can be a valuable tool when purchasing existing operations or used equipment, or even when transitioning away from the original operation in order to meet changing market demands.
General Repairs
In addition to the services listed above, it is important to recognize that any issue that comes up is likely to require immediate attention in order to avoid subsequent additional damage. Replace worn drum shells, gears, seals, and the like to avoid potentially greater repair costs in the future.
Tolling
Another way manufacturers can cut costs during slow times is to utilize tolling facilities. A tolling facility manufactures product, be it a fertilizer, soil amendment, or chemical product, on a contract basis, allowing the producer to hold off on building or upgrading their own production facility.
Conclusion
Investing in existing plant infrastructure is an excellent way to protect assets during uncertain times. This is particularly true of rotary drums, which represent a substantial investment in any operation. Through the services listed here, rotary drums can be kept in optimal condition while contributing to the bottom line through increased efficiencies, helping to make the slowdown a little less impactful.
FEECO is a leading provider of parts and service support for rotary drum equipment, including dryers, coolers, kilns, calciners, and agglomerators. Our experienced Customer Service Team can assess your unit and help you to optimize current operations, gain production capacity, and resolve any identified issues with expertise and efficiency. For more information on our parts and service support, contact us today!