Upgraded plate rolling system boosts fabricator’s output, quality

A new plate rolling machine increased quality and capacity at Membrane Process and Controls.

Situation

Engineering and custom metal fabrication firm Membrane Process and Controls (MP&C) serves multiple sectors, including wastewater treatment and pharmaceuticals, from its Edgar, Wis., facility. Its capabilities range from the design and fabrication of stainless steel processing equipment to the installation of membrane filtration systems, CIP skids, ASME pressure vessels, atmospheric tanks, and process piping.

The fabricator recently encountered a hurdle when producing rolled tank shells. Its outdated Roundo PS-310 plate roll, which lacked CNC capabilities, no longer met the company's evolving requirements. Managing multiple operators was a challenge, and training became increasingly burdensome. The capacity of the outdated plate roller also was a limiting factor.

Always on the lookout for new technologies to enhance the effectiveness and value of its projects, MP&C knew it was time to upgrade its rolling process.

Resolution

The company reached out to Faccin Group to research new plate roller options. After careful consideration with the help of the Faccin team, MP&C decided on the Faccin 4HEL-3539 model four-roll plate roll with Siemens PGS-Ultra CNC. Top and side support completed the line for total automation.

Once that decision was made, the machine arrived within five months. “This met our timeline perfectly, as we are doubling our shop capacity, and the transition worked out well,” said Luke Stencil, maintenance supervisor at MP&C. “The day of delivery was exciting, seeing a brand new piece of equipment being placed in our facility. Our employees were eager to learn how to use the new equipment, and we knew we would put it to good use immediately.”

The machine has boosted the fabricator’s manufacturing output of tank shells and circular metal forming shapes.

“We rely on the accuracy of the machine to maintain our customers’ highest tolerances,” said Stencil. “Time and time again, it is proving itself, whether we are rolling something big or small, thick or thin.

“Right away, we are noticing an incline in quality, as this machine meets tolerances better and overall provides a better product,” he added. “The roller cuts our production time down drastically when making tank shells compared to our previous plate roll. This is incredibly helpful, as we work in a world where lead times are tight. Less time spent means less overall money spent, so the cost savings is valuable as we are able to produce more in a single day.”

Stencil also noted that the machine has been safer to work around, as most of the moving parts are contained.