Investment in machinery and equipment is the largest capital expenditure
for a die caster. So maximizing their performance, in a cost-effective
manner, is crucial. After many years, the performance of a die casting
machine deteriorates to the point where increased flash and increased
cycle time demand that something be done.
Benefits of Remanufacturing
While purchase of a new die casting machine to replace an existing machine
which has seen a number of years of service may seem the obvious solution -
and may in fact be the appropriate choice in some circumstances - it is a
costly one. In most cases, a comprehensive remanufacture of the existing
machine by a qualified, quality-driven, technically capable specialist will
add many years of reliable service life to the machine and provide
"good-as-new" (or better!) machine performance at a fraction of
the cost of a new machine (typically, 1/3 to 1/2 the cost). In fact, by
updating the machine to incorporate the latest technology and operator
safety improvements, the die caster can "customize" the
already-familiar machine to achieve maximum performance and productivity for
that plant's specific operating environment.
In addition to the savings in machinery investment, opting for
remanufacturing has a number of other economic benefits, including:
- Faster delivery than most new machines
- Reduced payback period
- Use of existing foundations, plumbing, and electric
- Reduced installation time
- Elimination of training for operator & maintenance personnel
- Use of existing spare parts inventory
Rebuilding vs. Remanufacturing
These terms can be confusing, but they are most definitely NOT the
REBUILDING involves repairing one or more specific problem areas, such
as worn parts. Most rebuilders are generalists, covering a wide range of
machinery in many different industries, and are therefore not likely to be
specialized in die casting machines. Even worse, many of them are also
used equipment dealers - so it is quite possible they are making repairs with
an eye towards resale, fixing the essential problems and the cosmetic ones,
not looking for parts about to cause problems, and certainly not doing a
comprehensive inspection of the entire machine.
REMANUFACTURING involves a complete teardown of the entire
machine, followed by a thorough inspection and evaluation of all
components (large and small, mechanical and electrical), not just the critical
elements. This includes seals, bearings, cylinders, fasteners, gearboxes,
chains, pins, hydraulic lines, relays, solenoids, motors, pumps, tie bars,
linkages, bushings, and so on. Any questionable items are replaced, and all
critical components are restored to manufacturer's specifications and
tolerances, or better. Any original design defects are corrected. Finally,
any specified safety and technology upgrades are installed. Then, the
reassembled machine is thoroughly checked out and dry-cycled for 8-16 hours
before shipment. A remanufactured machine not only looks like new, it
performs like new - and frequently, better than new.
Choosing a Remanufacturer
For this important job, it's important to choose a superior vendor. Here
are some questions you should ask:
Tymac Controls Corp. has decades of experience serving die casters worldwide,
in machinery manufacturing and remanufacturing, hydraulic and electronic
control systems, MIS systems and custom software.
- Do you specialize exclusively in rebuilding machinery for the die casting
- Do you have the necessary equipment and engineering and fabrication
expertise to perform the work capably and efficiently?
- Do you have a reputation in the die casting community for quality work
and after-sale service?
- Do you have the necessary mechanical, hydraulic, electrical, programming,
and control systems resources to accurately diagnose and treat potential
- Do you have the facilities necessary to dry-run and thoroughly cycle the
remanufactured machine prior to shipment?
- Do you offer a comprehensive warranty for all work performed?