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aluminum plant equipment repair

Aluminum Foil Plant Preventative Maintenance

One of Louisville’s largest customers pro- duces aluminum foil. Manufacturing foil starts with aluminum rolls up to 1/2” thick. This plant takes the ½” thick thru mill 6, which reduces the foil thickness to less than 0.100” thickness. From mill 6, the rolls are rolled thinner in mills 3-4-5. After several passes thru these mills, the rolls go to mill 1-2 to roll to thickness required for commercial or residential use. Standard household or standard duty aluminum foil is 0.00063” thick and extra heavy duty foil is 0.00094” thick. Both thinner than 1 thousandth of an inch. Rolling aluminum foil this [...]

Aluminum Foil Plant Preventative Maintenance2023-03-13T10:55:03-04:00

Catastrophic Bearing Failure

An Aluminum Foil manufacturer experienced catastrophic bearing failure on a combustion air furnace fan. When the bearings failed, the fan wheel made contact with the fan housing. The combustion air fan provides air to the furnace gas burners. The furnace heats the aluminum foil rolls to burn off the oil used to manufacture aluminum rolls when the aluminum passes through mills and separators. Horner Fan received the damaged fan. The incoming inspection revealed the fan hub was cracked and along with the fan wheel damage – bent/cracked blades and ripped off back plate, Horner Fan recommended to manufacture a replacement. The [...]

Catastrophic Bearing Failure2022-01-28T15:18:37-05:00

Out Of Production Lock Nuts

One of Horner’s customers is a major supplier of automotive grade aluminum for major manufacturers of car and truck bodies. After the aluminum passes through a set of rolling mills to reduce the material thickness, the sheet passes through an annealing furnace to reduce material stresses from the rolling process. The annealing furnaces have fans circulating the furnace hot air to evenly distribute the heat to prevent hot spots. This particular fan assembly from one of the annealing furnaces had experienced a bearing failure. The shaft was initially sent to Horner Washington St to evaluate the damage to the main shaft. [...]

Out Of Production Lock Nuts2022-01-26T23:07:37-05:00

2000 HP Aluminum Plant DC Motors

An Aluminum Rolling and Recycling plant, a good Horner customer in Terre Haute brought Todd Cochran (Sales) a problem/ or opportunity to Indianapolis Field Service. The customer has two, 2,000 HP DC motors coupled together, to deliver 4,000 HP to their mill. These motors are about 5-6 foot square, and 10 feet long each. The inside motor, the one coupled between the mill and the second motor, failed and had to be replaced with a spare. This is not something they can shut down for a couple of days. Of course this happens when the Indianapolis Field Service group is working [...]

2000 HP Aluminum Plant DC Motors2021-01-08T23:55:43-05:00
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