machine shops
like Production Engineering were compacting chips and not always cost
effectively. Kurt recognized this opportunity and focused on developing new chip
compacting technology based on its own experience rather than replicate what was
already being sold to the market."
Dense
eight-to-One Compaction Ratio Sets New Industry Standard
"The big
difference we saw with Kurt's Chipmunk compactor over what was out in the market
was its simplistic design and its kinetic energy drive which produces a very
high eight to one compaction ratio," said Emmert. "We wanted to produce the
densest chips possible for the best payback and lowest cost of operation so the
density quality of the briquettes was very important to us. Also, the Kurt
Chipmunk itself was a high volume machine for its compact size, was simple and
easy to operate, and we were confident in Kurt's service support since we used
their Anglock vises for many years."
"The Kurt
Chipmunk can compact chips more consistently and efficiently than conventional
hydraulic compactors that require twice the horsepower," said the spokesperson.
"It has a single auger feeding design which operates from a powerful but simple
compression plate which forms and compresses the wet chips into 3-1/2 inch x
1-1/4 inch continuous extruded briquettes. It utilizes a power-saving 30 HP main
motor that is about half the size required in conventional compactors, which
produce less than half of the Chipmunk's output. Also, this patented compactor
design compresses out up to 98 percent of residue coolant so neat, firm
briquettes are produced that are dry to the touch and require no further coolant
removal. The recovered coolant collects in a separate reservoir at the base of
the Chipmunk system ready for filtration and reuse. The Kurt Chipmunk has a
payback of one year or less on most installations."
Chipmunk Setup at
Production Engineering Streamlines Briquette Storage and Pickup
"Upon
arrival of the new Chipmunk compactor, we partnered with a new local recycler
and changed our entire method of chip pickup, weighing and payment," said
Emmert. "Instead of 55 gallon barrels, our new recycler provided us with gaylord
boxes 40 inches x 48 inches x 48 inches that hold 3,000 lbs of compacted
briquettes. The empty boxes are delivered to us in a truck trailer that is left
parked at a loading dock in the back of our plant. The Chipmunk compactor is
located near that dock. As chips are produced in our various machining centers,
they are immediately placed in movable carts that hold a cubic yard of chips and
are lined up for loading into the Chipmunk compactor. It takes just a few
minutes to load a day's worth of chips, which are compacted into briquettes long
before the shift is over that day. Also, once the Chipmunk hopper is loaded, the
system operates unattended, automatically filling each box with dense, dry
briquettes. When a gaylord box is filled, it is weighed and then loaded into the
truck trailer. An empty box is substituted for it with the process repeated
until the trailer is filled."
"This
process really is much more efficient than the old method," said the
spokesperson. "A fork truck stacks the fully enclosed briquette-filled boxes
neatly inside the trailer. When filled, a replacement trailer load of empty
boxes is delivered and the full trailer driven to the recycler. None of the
chips accumulate inside Production Engineering, either on the plant floor or at
the back of the plant. All chips are processed the same day through the Chipmunk
compactor as they are produced. The recovered coolant is filtered and readied
for reuse. This new method eliminates any chance of wet chips draining off
coolant onto the floor or parking lot surfaces and creating difficult cleanups."
"When the
recycler receives the trailer full of loaded boxes, they are emptied and the
briquettes weighed as a unit. We know ahead of time what each full box of
compacted briquettes weighs, give or take a few pounds, so there are no 'short
weighing' problems. A settlement report and check is sent to us by mail based on
market prices for compacted 6061 aluminum chips every 30 days. The settlement
report is verified against the weight of briquettes sent out to make sure we are
getting full credit. The trailer pickup/drop-off cycle occurs about once every
15 days, filling a truck and then starting over with an empty one. There is no
deduction for coolant residue in the briquettes because it has all been removed.
The only charge to us by the recycler is $90 for pickup of each trailer load."
"We
improved the sale of our aluminum chips on average by 10 cents a pound using the
Kurt Chipmunk compactor," said Emmert. "At 3,000 lbs of chips a day, that is
very important to our profitability. And the higher return gets better as the
price of aluminum increases. However, our using the Chipmunk system is as much
about improved plant processes as it is about getting more money out of scrap
dealers."
"Having a
rigid, flow-through process for chip handling improves a lot of things. Our
workers, for example, understand that chips are a by-product and must be treated
with as much care as finished parts. Nothing is wasted or discarded. All chips
and coolant are saved. The Chipmunk system itself takes up no more space than a
standard sized machining center or less than the amount of space originally
required for the old barrel method of accumulating chips. Everything is a lot
neater and cleaner. We've always had clean floors but now we have immaculate
floors with not a trace of spilled coolant or stray aluminum chips. Floors are
coated with a high gloss sealant making them very attractive and non-slip so
they're safer and easier to keep clean. Also, our customers appreciate top-notch
housekeeping because they know it contributes to a more positive worker attitude
that contributes to quality and efficiency."
For more
information contact:
Steve Kane
Kurt
Manufacturing Co.
Chip
Solutions Division
1325 Quincy
Street NE
Minneapolis, MN 55413
763-572-4631
www.kurtchip.com
E-mail:
skane@kurt.com
Clint
Emmert, Vice President
Production
Engineering Corporation
3515
Marshall Street, NE
Minneapolis, MN 55418
612-788-9123
Fax:
612-788-0472
www.pecorp.net
E-mail:
clinte@pecorp.net
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