INDUSTRIAL CASE STUDY
ABRASION-RESISTANT PIPE PROVIDES LONG OPERATING LIFE
Eck Industries, Manitowoc, WI, operates a specialty aluminum foundry that manufactures various sand-cast aluminum parts for automotive, defense, and other industries. The foundry operates 24 hours a day, 7 days a week, and makes more than 3,500 different cast aluminum parts weighing as little as 1 ⁄ 2 pound to more than 2,000 pounds. CUSTOMER – ECK INDUSTRIES
PROBLEM
SOLUTION
Sixty-six tons of sand were conveyed through 4-inch
Eck Industries began replacing black iron pipe sections with Ultra Tech 4-inch diameter, Schedule 80, abrasion- resistant pipe whenever the old pipe wore out and eventually completely switched over. When Eck Industries decided to expand, they again used Ultra Tech abrasion-resistant pipe for a new thermal sand reclamation system. Eck Industries plans to use Ultra Tech for future projects.
diameter, Schedule 80 black iron pipe each day. Within 6 months, the pipe would wear and sand would spill out into the foundry. Conveying and production lines would shut down until repairs were finished. After 3 months, the repairs would wear out and pipe would be replaced, which meant production was closed again. Eck Industries needed a way to increase the pipe operating life in order to decrease production downtime and maintenance costs.
“Since this pipe can last up to 6 times longer than black iron pipe, we significantly reduced downtime and maintenance costs over the years because once a pipe section was replaced, it didn’t have to be touched again for 2 to 3 years,” says Gass.
“Even though the supplier’s pipe costs a little more than the black iron pipe, we’ve seen a cost savings over the long run because of its extended operating life,” says Tom Gass, vice president of material purchasing at Eck Industries. “We’ve also seen a significant decrease in our operating costs because of the reduction in downtime, maintenance, and crane rental costs. To further reduce our maintenance costs, we don’t worry about repairing the pipe with patches anymore. After we install the pipe, it will stay in place until it wears out and then we’ll replace it.” RESULTS
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