Machinery Rebuild and Repair

‍All Enterprises Inc. was tasked with the challenging project of restoring a severely damaged screw press at a facility in San Diego. The machine had been out of operation for three years, with multiple mechanical contractors unsuccessfully attempting to repair it. All Enterprises Inc. took on the project with the determination to get it operational.

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Challenges

• Initial Condition and Previous Attempts: The screw press had been damaged for three years, with multiple mechanical contractors unable to repair it, leading to the machine being repeatedly disassembled and reassembled without success.
• Complexity of the Press: The press featured a flywheel assembly that required removal through the facility's roof, necessitating coordination with the FAA and local authorities for crane operation, permits, and logistics due to the facility's proximity to an airport.
• Damaged Components and Design Flaws: All Enterprises Inc. discovered that a previous repair attempt had further damaged the press, including a faulty bearing and a flawed original factory design that prevented the press from functioning correctly.

Innovative Solutions

In-depth Diagnosis and Modification: Through careful analysis, All Enterprises Inc. identified that the original design of the press was flawed, particularly with the bearing arrangement. The team modified the press by adding an additional bearing to ensure proper alignment and functionality, addressing the core issue that had eluded previous repair attempts.

• Precision Machining and Custom Fabrication: All Enterprises Inc. removed the press and transported it to their facility for detailed machining and part repair. This included custom fabricating a new bearing arrangement, modifying the shaft with heat-treated material, and making new bronze oil seals and lock nuts, all of which were critical to the machine's operation.
• Expedited Supply Chain Management: The bearings required for the repair were metric and had a 12-month lead time from the official supplier. Leveraging decades-long relationships with vendors, All Enterprises Inc. sourced the bearings in just two weeks, significantly reducing the project's timeline.

Project Outcome

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The screw press was successfully restored to full operational capacity and has been in service since 2017 without any issues. All Enterprises Inc.'s modifications not only fixed the immediate problems but also enhanced the machine's longevity by incorporating modern materials and design improvements.

Key Highlights

• Restoration Success: Overcame the challenges of previous failed repairs and restored a screw press that had been out of operation for three years.
• Design Improvement: Identified and corrected a fundamental design flaw by adding an additional bearing, which has kept the press operational since the repair.
• Vendor Relationships: Expedited the procurement of critical components, reducing lead times from 12 months to two weeks.
• Precision and Expertise: Demonstrated expert-level precision in machining, custom fabrication, and assembly, ensuring the machine's long-term functionality.

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For more information or to discuss how All Enterprises Inc. can assist with your machinery repair and rebuild needs, please contact us.

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A facility experienced recurring issues with their press, which broke tie rods every year under the maintenance of another contractor. All Enterprises Inc. was brought in during a Christmas shutdown to de-stress and properly repair the press.

Challenges

1. Recurring Tie Rod Failures: The press broke tie rods annually, indicating improper alignment technique and maintenance methods by previous contractors.
2. Inadequate Previous Repairs: The previous contractor used overtonnage on the press to tighten components, which was insufficient and led to repeated failures on an annual basis.

Innovative Solutions

All Enterprises Inc. employed a strategic approach to address these challenges effectively:

1. Comprehensive De-Stressing: The team completely de-stressed the press by removing all the nuts, cleaning every component, and ensuring proper alignment and function.
2. Calrod Utilization: The tie rods were drilled for calrod holes, which were used for heating and proper stress distribution. This method provided a more effective and lasting solution compared to the previous overtonnage approach.
3. Experience: Having extensive history working on presses with similar issues, we were able to explain to our client how the repeated approach of using overtonnage was the root cause of the issue for tie rods breaking, and offer an alternative approach that we know, through experience, has resolved similar issues in the past.

Project Outcome

The project was completed successfully during the Christmas shutdown, with the press going 15 years without breaking a tie rod after the repairs made by our team. All Enterprises Inc. demonstrated their capability to provide long-lasting and effective solutions for complex issues.

Key Highlights

• Project Complexity: Tackled recurring tie rod failures by employing innovative de-stressing and heating techniques.
• Precision and Efficiency: Utilized calrods and proper tooling to ensure the tie rods were correctly stressed and the press was effectively repaired.
• Long-Lasting Solution: The press operated without breaking a tie rod for 15 years after the repair, showcasing the durability and effectiveness of the solution.
• Expertise: Extensive experience in handling complex machinery repairs and providing innovative solutions for long-term reliability.

For more information or to discuss how All Enterprises Inc. can assist with your machinery repair and maintenance needs, please contact us.

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An aluminum extrusion facility experienced recurring issues with their 3,000T extrusion press housing and needed help replacing it. All Enterprises Inc. was brought in under the client's Holiday shutdown to perform the replacement, which included a new main housing, tie rods and super nuts, as well as a new main housing bushing and gland ring.  

Challenges

1. Recurring Equipment Failure: The press housing kept cracking, necessitating a complete replacement to ensure continued operation.
2. Tight Timeline: The entire project had to be completed within a two-week Christmas shutdown period, requiring efficient management and coordination.
3. 24/7 Operations: To meet the tight deadline, double shifts were necessary, requiring meticulous management of both shifts to maintain 100% productivity.
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Innovative Solutions

All Enterprises Inc. employed a strategic approach to address these challenges effectively:

1. Disassembly and Reassembly: All Enterprises had 24-hour coverage on the press, keeping 100% productivity throughout the shutdown in order to meet the tight deadline.
2. Alignment: All Enterprises team was able to perform the meticulous alignment process and ensure the press was running square on startup.
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Project Outcome

The project was completed successfully within the two-week Christmas shutdown period. The new press housing was installed, and the press was reassembled and made fully operational. All Enterprises Inc. demonstrated their capability to handle tight timelines and complex projects with efficiency and expertise.

Key Highlights

• Project Complexity: Tackled recurring equipment failure with a complete replacement of the press housing under a tight shutdown timeline.
• Precision and Efficiency: Managed double shifts to ensure continuous productivity and successful project completion within the two-week period.
• Comprehensive Solution: Provided a complete disassembly, reassembly, and installation of new components, ensuring the press was fully operational and reliable.
• Expertise: Extensive experience in handling complex machinery repairs and replacements, providing effective and timely solutions.
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For more information or to discuss how All Enterprises Inc. can assist with your machinery repair and replacement needs, please contact us.