Our customer in Malaysia (FIW) wished to upgrade their existing Galvanising Line with roll coating technology, to apply passivation to the finished product. The customer also proposed to include a second coater machine to apply a resin product to the finished galvanised product.
Bronx was contacted to discuss the most practical, cost effective and least disruptive solution. However, there was a larger issue at hand: limited space to fit the equipment.
Bronx Group was given the challenge of fitting its equipment into a meager 11 metres. A horizontal solution was not an option.
As an existing customer, we had a healthy working relationship which was important when looking to include new technology and product development for this one-off project.
The equipment included two custom built Vertical Coater Machines, Gas Fired Infra Red Drying Technology, strip cooling (prior to top turn roll, to quench the high drying temperature of the resin coating), 3 level mezzanine floor, numerous pinch and deflector rolls, electrical system. Bronx also provided the services of our site engineers (for installation and commissioning), project management, service engineering and the Bronx technology team on-hand.
To prevent a lengthy shutdown of the existing line while the modifications and installations were being implemented, a carefully detailed project schedule was put in place. It was critical to have a constant line of communication with the client, as disruptions to current production were to be minimal.
Bronx successfully commissioned the upgrade earlier this year. The coater machines, following installation were soon performing to the their optimal level, as well as achieving the objective of ensuring the correct drying temperatures were met.
The Gas Fired Infra Red Dryer included section burner control. This control was a critical part of the process when various cross sections and PMT temperatures were being produced.
Our client can now successfully continue its operations with improved equipment and technology, as well as generating greater business.