A Case of Boosting Production
KALLER® High-Performance Gas Springs and Hose Systems Boost Production at Walsall Pressings
In a successful collaboration between KALLER UK and Walsall Pressings, based in Walsall, West Midlands, UK, a critical issue affecting production efficiency was resolved. Walsall Pressings faced persistent downtime with one of their deep draw tools, which operated continuously at approximately 6 strokes per minute in dedicated press lines. The tool, crucial for manufacturing gear boxes from double skin laminated steel, had to be periodically removed for maintenance. Impressively, this tool yielded around 7,000 sumps per week.
Walsall Pressings has extensive expertise in crafting engine and gearbox sump components from double skin laminated materials. Their proficiency in deep draw presswork and progression tooling is well renowned. The manufacturer adheres to the highest technical standards with more than 70 years of manufacturing experience giving Walsall Pressings a proven record as a world class supplier to the automotive industry and other similar markets.
The Problem:
- Persistant and unnecessary downtimes
- Costly replacements every few weeks
- Frequent maintenance on the tool
However, persistent downtime posed a significant challenge, stemming from gas spring failures and hose system leaks. Gas springs or their seals required replacement every two weeks, necessitating the removal of the tool from the press for maintenance. Additionally, hose leaks forced tool recharging every two hours, causing even further production interruptions.
The Solution:
- Replaced with reliable TX Gas Springs
- Installed EZ Hose and fittings with Dual Seal™ and anti-vibration technology
- Has now operated over 8 months without a single gas spring failure or hose leak
Leveraging their extensive experience in the high-volume Metal Pressing market, KALLER® confidently offered a solution to increase production and mitigate downtime caused by gas spring failures. They equipped the tooling with ten KALLER TX 4200 Gas Springs with a 175mm stroke, as well as EZ Hose and fittings featuring Dual Seal™ and anti-vibration technology.
This replacement of KALLER® springs has now operated for over 8 months without a single gas spring failure or hose leak; eliminating production breaks and lost time for Walsall Pressings.