Case Studies
Case Studies
The Proof is in Our Work
- All
- Assembly Tools & Material Handling
- Compressed Air Systems & Equipment
- Paint Finishing & Fluid Handling
Compressed Air Systems & Equipment
Compressed Air Controller Technologies
Solutions: Advanced Compressed Air Controller Technologies
C.H. Reed recently installed 2 Quincy QGV-40 air compressors, and 2 Quincy QMD-230 desiccant air dryers for a food flavorings producer in Maryland. The compressor/dryer pairs were designed to be split into two independent systems. The customer specified that they wanted automatic rotation of lead/lag between the compressors, and automatic backup if one of the compressors should fail. Using the technology that is built into Quincy’s Q-Controller, the C.H. Reed service department was able to far exceed the customer’s expectations. Taking full advantage of Quincy Q-Control technologies, we were able to automate rotation and back-up, pair the dryers with the compressors, custom program the dryers and compressors with Quincy’s ICONS (automatically sending alerts for any faults), and installed remote sensors so they get their pressure readings from the same place. Click here to read the full write-up.
Paint Finishing & Fluid Handling
Engineered Systems
Solutions: Meter, Mix, and Dispense
This customer needed a custom solution for an application that, in the end, could accurately portion and distribute small, precise shots of liquid. The Engineered Systems team at C.H. Reed fabricated a custom Graco 1052 Dispensit Valve with positive displacement metering rod. The Graco 1052 Dispensit Valve is a pneumatically-controlled valve with micrometer adjustable dispense volumes for accurate, repeatable shot dispensing. The liquid flows through the (yellow) needle with a rate that is adjustable in both pressure and volume.
Conclusively, this customer now has full control over the dispensed amounts of liquid, as it may vary during different project ventures. They simply adjust the micrometer setting to the exact gram needed for their application(s) and can trust that they will receive consistent, accurate results.
Paint Finishing & Fluid Handling
Local Print Manufacturer
Solutions:
This print manufacturer was looking to eliminate and reduce maintenance costs associated with their finishing process. C.H. Reed proposed the installation of hydraulic air motors rather than pneumatic motors. These hydraulic motors save exceptional costs by operating on 20% of the energy used by a pneumatic motor.
Paint Finishing & Fluid Handling
Contract Painter
Solutions:
This contract painter was experiencing inefficiencies in their painting process such as dirt in the paint, hard to mix 2-component paint, and paint/solvent waste. They wanted to advance their cost savings on wasted paint and solvent while increasing production and quality to show their true capabilities to new customers. To meet these goals, C.H. Reed installed automatic mixing equipment to give them a consistent mix quality, reduce color change time, and provide better waste contaminant.
Paint Finishing & Fluid Handling
Local Manufacturer
Solutions:
This local manufacturer had very large items that they needed to paint in a structurally sound and environmentally friendly environment. C.H. Reed designed and installed this custom spray booth which had an allotted slot in the roof for material handling crane access so the customer could safely and effectively maneuver the items with ease.
Paint Finishing & Fluid Handling
Metal Cabinet Manufacturer
Solutions:
This manufacturer was experiencing material handling issues which were causing them delayed process times. They wanted to improve the production process and integrate a complete system that lets them load the product, clean it, apply powder paint, cure it, and easily have it come off the line to pack and ship. C.H. Reed’s creative concepts and proposed solution resolved the material handling issue which significantly reduced production times.
Paint Finishing & Fluid Handling
Manufacturer of Portable Water Tanks, Containers, and Trucks
Solutions:
This manufacturer needed to increase their production times to keep up with demand. In doing so, they also needed to find a way to increase paint transfer efficiencies to save in material costs. The equipment previously being used to finish their product consisted of pressure pots with HVLP (high volume, low pressure) spray guns. Though HVLP guns typically do a good job, they were not maximizing their transfer efficiency capabilities in their process. C.H. Reed introduced them to Graco’s state-of-the-art Pro XP85 Electrostatic Spray Guns along with 2 air assisted airless spray packages. Graco’s ROI calculator estimates this customer will experience a 50% savings in paint usage and will take approximately 6 months to be paid back on the purchase of the equipment.
Paint Finishing & Fluid Handling
Assembler of Aerial Lift Trucks
Solutions:
This customer needed to increase their production throughput in their painting process while reducing material and labor costs. They also wanted to convert from costly gallon containers to a 55 gallon drum application while maintaining a cleaner and safer work area. To eliminate the labor intensive & messy process of hand mixing (hot potting), C.H. Reed introduced them to Graco’s ProMix 2KS two component paint system with accurate ratio assurance for a superior finish quality. We also replaced over 95% of their one gallon paint containers with 55 gallon drums, drum agitators and an air operated elevator. On top of that, their electrostatic guns were upgraded to the much more efficient Graco 85KV spray gun, giving them maximum paint transfer efficiencies. Lastly, C.H. Reed eliminated one gallon solvent purging by installing two 55 gallon drums of solvent then changed out their solvent reclaim system. By doing so, it fixed the solvent reclaiming bottleneck issue by 75% resulting in more efficient production times and less material waste.
Paint Finishing & Fluid Handling
Electrical Equipment Manufacturer
Solutions:
Previously, this manufacturer was hot potting (the process of mixing multi-component paints by hand) which produces wasted material and increased cleanup time; both of which were affecting their bottom line. C.H. Reed’s solution for the customer was to introduce plural component mixing equipment as a direct replacement of their “hot potting” technique. Aside from saving on wasted paint & solvent, they also experienced increased mixing accuracies; leading to improved finish quality, a faster flush with less waste resulting in reduced disposal costs and less cleanup time, and peace of mind knowing that the quality equipment is exceedingly reliable operating in a general manufacturing setting.
Paint Finishing & Fluid Handling
Steel Storage Tank Manufacturer
Solutions:
This customer manufactures above-ground storage and processing tanks for a variety of different industries. They came to C.H. Reed looking for a cost effective solution to decrease material wasted during their painting process. Previously, they were “hot potting”, the process of mixing multi-component paint by hand. This process takes time, effort, and generates a lot of waste. By installing Graco Electronic Plural Component Proportioning Systems,they now have high-ratio assurance with easy-to-use components. Their new set-up offers extreme accuracies & flexibility (meaning less chance of paint failure in the field), increased efficiency (easy color changes), and less materials wasted in their painting process. On top of that, clean-up is now a breeze.
Compressed Air Systems & Equipment
Local Container Manufacturer
Solutions:
This customer had 7 vintage air compressors which were becoming obsolete & more expensive to operate due to inefficiencies. They needed to reduce their maintenance & energy costs so C.H. Reed replaced the 7, outdated compressors with 2 energy efficient units. After the job was complete, the 200 HP & 300 HP partially loaded compressors saved the customer approximately $100,000 per year in energy costs alone.
Compressed Air Systems & Equipment
Snack-food Manufacturer
Solutions:
As a food manufacturer, freshness is a top priority so they had a nitrogen generation system installed. That system required 1500 CFM of compressed air at 115 PSI. To help with energy efficiency in their plant, C.H. Reed installed 3, 200 HP variable capacity units as well as a desiccant dryer system and several large air receivers.
Compressed Air Systems & Equipment
Aircraft Turbine Test Facility
Solutions: Centrifugal Air Compressors
This aircraft turbine test facility was in need of a centrifugal compressed air system to drive an aircraft turbine for testing purposes to improve energy efficiencies as well as internal cooling of the jet engine. C.H. reed designed & installed the centrifugal unit to meet the customer’s specifications. We also provided them with a Hydrothrift closed loop cooling system, custom fabricated test piping, and a process gas chiller to help them meet their goals. This centrifugal compressor is located at Penn State University in State College, PA and was purchased through the Department of Energy-National Energy Technology Laboratory (DOE-NETL). To learn more about this project, contact C.H. Reed.
Compressed Air Systems & Equipment
Local Printing Company
Solutions:
Due to facility expansions, this client was in need of an additional air compressor on top of the 3 variable compressors C.H. Reed already installed. Since they were using 3000 CFM of compressed air, we recommended using a centrifugal, 700 HP unit with a Multiplex dryer to match their base loads. Also, C.H. Reed designed a system where this facility can reclaim heat off of the screw compressors to help save energy costs in the colder months.
Compressed Air Systems & Equipment
Injection Molding Manufacturer
Solutions:
This customer’s goals were to have an energy efficient, reliable compressed air system to reduce costs associated with their production process. With that in mind, C.H. Reed proposed and installed two Quincy 150HP VFD’s and two Quincy 75HP Power$ync compressors for maximum energy efficiency. With complete redundancy, they can now rotate units to reduce run hours and maintenance costs per machine. Additionally, a PPL Electric Utility rebate of $17,800 was obtained. A flow controller was also installed to reduce tank pressure from 100psig to 90psig and a differential pressure storage was required to maintain constant system pressure. All equipment was piped together using Transair Aluminum Pipe, featuring Y-pipes, which will reduce turbulence within the 4” manifold / eliminate back pressure. It should be noted the new units replaced three Quincy 75HP modulating units running 24/7 since 1982. This speaks to the quality and extended life cycle of Quincy products.
Compressed Air Systems & Equipment
Local Aluminum Foundry
Solutions:
A local aluminum foundry was experiencing issues with impurities in their castings and needed a quick, complete package solution to improve the quality of their finished product. C.H. Reed was able to determine that the impurities were being caused by the presence of hydrogen in the molten aluminum creating these gas pockets, which when solidified, become weak spots. The quickest and most effective way to get the hydrogen out of the process is with an on-site nitrogen generator. This introduces nitrogen into the molten aluminum and draws the hydrogen into bubbles that are released at the surface. Overall, we were able to help this foundry eliminate the impurities with a plug and play system that increases worker safety, is cost effective, offers a continuous supply of nitrogen, and improves the effectiveness with no gas wasted.
Compressed Air Systems & Equipment
Local Food Processor
Solutions:
Due to an increase in demand for a new product, a local food processor had to quadruple the size of their facility. Their compressed air requirement went from 50 CFM to over 900 CFM at different times. Because of the varying demand of air flows, C.H. Reed recommended 3 Quincy QSI500i (500CFM) air compressors with Power$ync lift valves for 100% backup. Also installed was a 1200 CFM heated blower purge desiccant air dryer that delivers energy efficient, high quality air. Integrated into this system are thermostatically-controlled louver vents for fully automatic module temperature control in the compressor room. Lastly, 4” Transair aluminum compressed air piping was used to increase installation efficiencies. In the end, this customer now has a high degree of redundancy built into their compressed air system with enough CFM to keep up with fluctuating production demands.
Click here to learn more about Quincy QSI Rotary Screw Air Compressors.
Compressed Air Systems & Equipment
Small Electronics Repair Facility
Solutions:
This customer was expanding into a new facility and needed a new compressed air system. Typically, air compressors in the electronic industry must be oil-free. Oil contamination in the compressed air can result in expensive maintenance costs, and in extreme cases, a complete production shutdown. But with proper filtration, you can use an oil-flooded unit to supply the plant. We proposed a 30 HP Quincy QGV Rotary Screw Compressor; engineered to deliver the lowest total cost of ownership. To complete the system, we installed a cycling dryer, an air receiver, particulate filter, coalescing filter, vapor filter, zero-loss drains, and 40 mm aluminum air pipe that feeds the plant. Lastly, this customer was able to obtain a $12,000 energy rebate to offset project costs.
Assembly Tools & Material Handling
Local Parts Manufacturer
Solutions:
This local manufacturer of engineered products needed to improve their overall quality by refining their critical torque accuracy, process control, and data collection.
Assembly Tools & Material Handling
Local Manufacturer
Solutions:
This local manufacturer wanted to eliminate ergonomic issues in their facility, improve the speed of their process, advance their critical torque accuracy, and improve their data collection procedures.
Assembly Tools & Material Handling
Local Manufacturer
Solutions: Torque
This manufacturer needed to improve their process speeds to meet production demands and eliminate some ergonomic related challenges their operators we experiencing.
Assembly Tools & Material Handling
Local Manufacturer & Supplier
Solutions:
A local manufacturer of storage and transport products needed to eliminate a material handling issue and speed up their assembly process while maneuvering a 300 lb. item around.
Assembly Tools & Material Handling
Lighting Manufacturer
Solutions: Torque
This manufacturer of exterior lighting products needed to increase their ergonomics and torque accuracies in their assembly process. Inline electric screwdrivers with balancers were just what they needed. These tools are flexible, accurate, comfortable and easy to maintain; increasing productivity, torque accuracies, and overall product quality.