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Selective Plating Crane Spear Repair
Selective Plating Print Cylinder Repair
Electroplating Drum Repair

Selective Brush Plating Case Study 1: Printing Machine

An eight colour printing machines rollers were damaged when an 8mm Allan key went through 6 cylinders damaging both plate and blanket cylinders. The cylinders were impossible to print on. The repair was needed immediately because the customers order book was extremely full.

Conventional Repair

  • Remove rollers from machine by breaking machine into three stations, 5 days each station.
  • Weld rollers, Grind back, Re-chrome, Re-grind
  • Assemble rollers in machine
  • Re Assemble stations
  • Test print and adjust
  • Time approx 4 weeks
  • Estimated cost Approx $80000-$100000

Selective Brush Plating Repair

  • Mask area in situe
  • Electroplate Copper
  • Dress Back
  • Cap with Nickel
  • Time approx 6 days
  • Cost Approx $25000

This example shows that a considerable amount of savings in time and money can be achieved by using the brush plating method.

The repair was carried out by two people working 10-15 hours a day. Test printing was carried out and a small amount of time was spent re-sizing a couple of low spots. Brush electroplating was the best method for this repair.

The work was carried out in situe, stopping expensive down time of 4 weeks and little stripping down was needed. The repair was started 1 day after the damage was reported. Printing machines are one of the most accurate machines to work on.

Selective Brush Plating Case Study 2: Food Processing Plant

The Chrome plated roller approx 20 meters long and 3 meters diameter was damaged by arc welding. This roller was used for drying tomato and corn pulp. The roller was heated and rolled through the pulp, the pulp was dried as the roller was rotated and then scraped off with a blade. The chrome was broken and the tomato and corn acid was eating into the steel base material.

Conventional Repair

  • Remove roller from machine.
  • Send roller to Europe for re-chroming as no bath for that size is available in Australasia
  • Weld Grind and re-chrome
  • Grind to size
  • Ship to New Zealand
  • Re-assemble roller
  • Time approx 14 weeks
  • Estimated cost Approx $100000

Selective Brush Plating Repair

  • Remove rollers from machine by breaking machine into three stations, 5 days each station.
  • Weld rollers, Grind back, Re-chrome, Re-grind
  • Assemble rollers in machine
  • Re Assemble stations
  • Test print and adjust
  • Time approx 4 weeks
  • Estimated cost Approx $80000-$100000

This example shows that a considerable amount of savings in time and money can be achieved by using the brush plating method. The repair was only small but very necessary; the steel was rusting under the chrome and lifting the chrome off the area around the damage.

Brush electroplating was the best method for this repair. The work was carried out in situe, stopping the down time of 14 weeks and no stripping down was needed as the damage was very accessible.

after the damage was reported. Printing machines are one of the most accurate machines to work on.

Selective Brush Plating Case Study 3: Hydraulic Crane Spear

The Spear on a portable crane of 15 meters in length was extensively damaged by electric cables, swinging chains and straps.  The crane was in for a major overhaul so the owner wanted the spear replaced. Replacement had to be imported from UK and time for delivery was 12 weeks.

Brush plating was another option as grinding and tank plating was in excess of the capacity in New Zealand.

Conventional Repair

  • Remove Spear Machine.
  • Import new spear and cylinder from UK
  • Time approx 12 weeks
  • Estimated cost Approx $40000

Selective Brush Plating Repair

  • Remove ram from machine.
  • Mask area’s
  • Electroplate copper
  • Dress back
  • Cap with nickel cobalt
  • Time approx 6 days
  • Cost approx $24000

This example shows that a considerable amount of savings in time can be achieved by using the brush plating method.

The repair was carried out by two people over 6 days on many dents, scores and scratches. Although the savings in money terms was not great, the time was more important as down time is money.  Brush electroplating was the best method for this repair under the circumstances.

after the damage was reported. Printing machines are one of the most accurate machines to work on.

Selective Brush Plating Case Study 4: Dairy Factory

The main air intake fan approx 2 meters diameter supplying the whole factory had fretted bearing journals and was making excessive noise and the bearings were beginning to move on the shaft.

Conventional Repair

  • Remove framing and guards around fan
  • Remove wall for access to Fan
  • Remove roof to take fan and shaft out of building six stories up
  • Hire crane from another area
  • Build up shaft (Welding)
  • Straighten Shaft after welding
  • Machine bearing journals to size
  • Return fan and shaft
  • Rebuild framework and guards around Fan
  • Rebuild roof and wall
  • Time approx 15 Days
  • Estimated cost Approx $65000

Selective Brush Plating Repair

  • Remove bearing Caps
  • Mask area in situe
  • Electroplate Copper
  • Measure
  • Dress Back
  • Cap with Nickel Cobalt
  • Time approx 8 hours
  • Cost Approx $2200

This example shows that a considerable amount of savings in time and money can be achieved by using the brush plating method. The shaft is not subject to any heat distortion and the work is carried out in situe.

One of the most expensive issues in this type of repair is the down time. By using the selective brush method most of the stripping down is not necessary.

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