A major aluminum extrusion manufacturer was experiencing a high rate failure rate of electric cartridge heaters used in their process. The heaters were seizing in the “pusher nose” – the ram used to push the heated billet through the die. These “nose heaters” must be kept hot to avoid pulling heat from the billet during the extrusion process.
When the heaters seize, they must be drilled out and the heater holes reamed to smooth out the bore which becomes damaged during the drilling and extraction process. When a new heater is inserted they now had a sloppy fit resulting in poor heat transfer from heater to pusher nose with the heaters sometime falling out. Needless to say, they were experiencing poor performance and high power usage because the heaters had to run hotter and longer to produce the necessary heat required.
The customer wanted a solution and our salesman suggested using a unique cartridge heater offered by one of our principals Dalton Electric Heating Co., Inc. The “split sheath” cartridges expand up to .020″ over their original diameter – enough to take up the slop created by repeated seizures and drill outs of the old conventional design heaters. The customer placed a small test order for heaters and we waited for the feedback. So did we solve the problem for the customer?
Yes, Bore seizures are non existent since switching to the Dalton heaters resulting in:
1. Reduction in replacement cartridge heater purchases
2. Huge savings in machine shop time drilling out seized heaters
3. Reduced Maintenance time pulling rams for service
4. Reduced power consumption. How much. We can’t say for sure because the customer does not measure or keep records of electric power usage by department but we typically see savings of upwards of 20%
This is an example of how we may be able to help you with a production or Maintenance problem in your plant. Please take a moment to watch the video of the benefits of Dalton Electric Heaters.
Incidentally – we have received several subsequent orders for the Dalton split sheath cartridges from a very happy customer.