Join us at AISTech 2023!

Kastalon Polyurethane Products is honored to once again be exhibiting at AISTech 2023 trade show on May 8-11 in Detroit, Michigan. Our booth, Booth #1623, will showcase our Koat-A-Roll® sleeves, coil floor pads, coil saddles and crane bumpers, as well as demonstrate how to install our sleeves, hot cast rolls and introduce our new “Magnetic” Fork-Kushion® truck lift bumpers! Be sure to stop by #1623 to chat with our experts or schedule a meeting for a more in-depth discussion.

Check out more about the AISTech Show, booth exhibitors and sponsors. Registration for AISTech 2023 is now open. See you at the show!

Mandrel Sleeve

Protecting Coils with Polyurethane

Originally posted January, 2021 By Beth Gainer on Jan 22, 2021, Metal Center News:

Protecting coils is vital to Bruce DeMent, CEO of Kastalon Polyurethane Products, Alsip, Ill. The company manufactures polyurethane products to protect coils’ surfaces. “The surface finish is critical and needs to be protected,” he says, adding that Kastalon’s mandrel sleeves protect the coated coil from metal-to-metal contact with the mandrel drum. Furthermore, the company’s mandrel sleeves help prevent common processing damage, such as reel breaks and head-end damage.

“Our sleeves help prevent coil slippage and increase the overall efficiency of the processing line,” says DeMent. “Our proprietary chemistries and manufacturing capabilities allow for Kastalon mandrel sleeves of virtually any size and hardness, and specific to each customer’s requirements.”

Kastalon coil floor pads protect coated coils during storage as well as serve an organizational function for the production floor.  The pads are available with and without fluid-collection capabilities. In addition, rollers used in uncoilers or surfaces that support the coil are covered in polyurethane so the surface where each coil is resting upon doesn’t dent the coil.

Kastalon also manufactures polyurethane devices in coil material handling and storage. “Everything that touches that coil can be covered with polyurethane – from a c-hook to the [forks] of a forklift truck,” says DeMent.

While polyurethane is more expensive than rubber, the former lasts 10 to 20 times longer than the latter. In addition, polyurethane requires less maintenance than rubber, according to DeMent. The equipment is operating longer and doesn’t have as much maintenance, resulting in cost savings.

“Polyurethane is extremely durable and yet cushions the coil so that it doesn’t get edge damage,” says DeMent. “The polyurethane floor pads protect coils by keeping them off the floor.”

“Everything is protected.”

 

New Summit Lathe Roll Grinder

July 2020, Kastalon has purchased and installed a new Summit roll lathe to further enhance our large roll manufacturing and repair capabilities. Kastalon now offers the most comprehensive roller services in the industry.

The Summit lathe/roll grinder allows Kastalon to not only machine metal, but to turn, mill, groove, and grind polyurethane and rubber covered rollers to ultra-precise diameters, geometric finishes, and straightness specifications. This CNC machine has a capacity of 48 inch finished diameters x 20 feet CC (1.22 x 6.1 meters) and almost 50,000 lbs with full CNC grooving. Simple to highly complex and precise grooves and finishes can be produced with this state-of-the-art equipment.

Kastalon’s roller capacity ranges from fractional diameters and face lengths to 62 inches in diameter x 30 feet overall length (1.57 x 9.1 meters). Kastalon’s polyurethane roll coverings are available from 20 Shore A to 75 Shore D (baby’s skin soft to bowling ball hard, and anywhere in between) with surface finishes and groove patterns to optimize your roller’s performance.

We’ve combined chemistry and mechanics just for you. Contact Kastalon today and bring the Kastalon’s advantage to your operations.

What does a dead blow hammer have to do with success at a Tube Mill?

Heavy duty polyurethane Dead Blow HammerAccording to Wikipedia “A dead blow hammer is a specialized mallet helpful in minimizing damage to the struck surface and in limiting peak striking force, with minimal elastic rebound from the struck surface.”


So here is the STORY…
A tube mill’s high performance automated systems are designed to keep things moving, however, one tube mill had an issue with their pipe bouncing back too far when they impacted their adjustable pipe stop bumpers. The bumpers were designed to stop the tube and prepare them to be fed into the next area of the line.

The bouncing of tubes was causing misalignment and jams. The line then had to be shut down until the jam could be cleared. This was a continuous issue so the mill staff assumed that the hardness of the bumper needed to be adjusted, however, that was not the solution. The problem was so severe that the bumpers were causing a bounce back as far as 18 to 24” on large pipes and 8 to 12” on smaller pipes.

Fortunately, the mill contacted a representative from Kastalon to get a second opinion. Kastalon’s expertise in chemical engineering was able to determine that the hardness was not the issue, the physical and mechanical properties of the polyurethane bumper needed to be adjusted to allow the bumpers to absorb the energy rather than rebounding it. What they needed was a “dead blow bumper”.

polyurethane dead blow bumperOnce the bumpers were replaced by a proprietary Kastalon polyurethane bumper, the results were immediate and dramatic. The bounce of large pipes was reduced to 4-5 inches and the small pipes were only bouncing back about an inch.

Regardless where polyurethane is used, the secret is not just the hardness of the material, but how the material needs to work to its optimal performance in that application and environment. This is where Kastalon’s “engineered to fit” philosophy puts the emphasis on the desired result and the environment that a part is operating in. Even if it is a simple bumper!

Kastalon Makes Big Dollar Difference for Rewinding Coils

In February of 2007 Kastalon was called to a Steel Mill for interest in our mandrel sleeves. We were called because this particular customer was having issues with the rewinding of their steel coils, as a result of the mandrel sleeves that were being used. They had also tried a few different mandrel sleeves from different vendors without the satisfaction they were looking for. Along with the operating issues, they were just not experiencing a longevity that they felt was adequate.

This particular line was a high speed steel processing line that converted hot band to automotive/appliance grade steel. The area of concern was at the end of the line where they have two rewind mandrels, that they alternate rewinding their finish product with. Most of their steel is considered exposed steel and they guarantee to their customers, 100 % coil usage.

Kastalon met with this customer and discussed their needs and concerns for this particular problem. We obtained drawings of their steel mandrel and engineered a mandrel sleeve that we felt would meet and exceed all of their expectations. In March of 2007, this customer placed an order for one mandrel sleeve for trial. The sleeve worked right out of the box and they ran it for three months, not experiencing any of the issues they had experienced with the prior sleeves. In July of 2007, they placed an order for the second sleeve and outfitted both of their mandrels with Kastalon Mandrel sleeves. They continued to see no reoccurring issues seen from the prior sleeves so they purchased two more sleeves as spares in November of 2007and continue to run problem free. Soon after the two spare sleeves were delivered to the customer, I stopped out and met with the customer to offer them with some tips on how to store and add operating life to all four of their mandrel sleeves. Tips that were never offered to them from previous suppliers.

In June of 2009 an order was received at Kastalon, Inc. for one sleeve. We called the customer to check in and we were told that they had an operator error and that one of the sleeves was tore and that they had to take it out of use. We asked them why they didn’t call us out to take a look at the sleeve before that was determined. They responded that the operator admitted to his error. And that the sleeves were just inspected a few weeks prior and looked as good as new, other that being oily from use. In November of 2011, two more sleeves were ordered. The customer was concerned that they have never had Mandrel Sleeve last this long and wanted to add two more to their inventory in case of a sleeve failure.

Since March of 2007, Kastalon has supplied a total of seven Mandrel Sleeves to this particular line. As of April of 2012, three of the four original sleeves provided by Kastalon are still in use. Remember, one was taken out of use due to operator error. This particular line is considered a High Speed, High Tension, Dual Rewind line. This customer has averaged 1,125,000 tons of steel per year that has been recoiled on our sleeves at an average speed of 1800 feet per minute. Their steel is considered very high quality steel which also adds something to say about our sleeves. (If our sleeves had poor cut resistant properties, we could also create them quality issues with their thinner gauge steel. But they have not experienced any of that.) Our customer has worked with us and together we engineered a sleeve that would meet and exceed their expectations. To say that they are satisfied with Kastalon Mandrel Sleeves is an understatement.

Update: 8/1/14
This customer placed an order for two more Mandrel Sleeves in July of 2014. Two of the original sleeves from 2007 finally wore out. That brings the total amount of sleeves ordered to 9 since 2007. Six of the sleeves are still in working order and are in their rotation being swapped out during downturns every three months.

Total cost of the nine sleeves that have rewound 9,000,000 tons of steel since 2007 have produced an operating cost for Kastalon’s Mandrel sleeves of $0.07 per thousand tons.

Maximizing Quality and Yield by Al DiZanni

Increasingly, competitive markets are pushing tube makers to reduce costs while improving quality.

The surface and edge condition of incoming coils has a significant impact on processing cost and quality. Scratch-free surfaces are important when processing polished, plated, or painted tube. However, scratches also can lead to weaknesses in the tube wall. This can be important for pressure tubing as well as mechanical tubing. Stresses can concentrate along scratches in mechanical tubing that is bulged or formed. Scratches can also concentrate stress in pressure tubing and create a weakness in the wall. This consideration is more critical for nonferrous materials.

Incoming material with a poor edge condition can lead to increased cost because of additional reprocessing, reduced yield, inspection cost, and the general inconvenience of returning the material and seeking credit for defective material from suppliers.

Producing, rolling, and processing coils influence its surface and edge condition. Surfaces and edges can also be compromised when they are handled during basic processes such as slitting, painting, annealing, and rolling.

Coil handling and protection also influence surface quality. This article examines typical problems in coil handling and how to maintain quality stock on the warehouse and mill floor.

Coil Handling Challenges and Answers
Beginning with the final stage of production, the finished metal surface is vulnerable to damage. Worn bridle, passline, pinch, tension, or other rollers that contact the metal as it is rolled can scratch surfaces. Slippage through or across rollers also contributes to scratching. To prevent slippage, these rollers can be covered with materials that provide traction and are softer than the metal, including rubber, polyurethane, and plastic .

Winding. Another potential source of damage is the expanding mandrel used to hold the coil while it is unwound and rewound during processing. These mandrels open and close when loading and unloading coil. To make this movement possible, the mandrel has segmented leafs that have gaps between them when expanded. The edges of these leafs can mark the inside of the coil.

When the metal is wound, it may bend at the edge to wind in a straight line to the next leaf edge. This is a condition called reel break. These breaks can print through many wraps before they soften enough to stop deforming the metal. In some severe cases, breaks can cause damage extending as much as 1/2 inch into the coil, potentially resulting in the loss of a 1-inch thick portion of metal out of the coil eye.

Excessive mandrel wear causes the leafs to get out of level and exacerbates reel breaks. Rubber or polyurethane sleeved (also call boots) can be used to minimize or eliminate this damage. A mandrel sleeve cushions the edge of the leaf and distributes the bending force over a wider area, helping to eliminate plastic deformation of the metal.

Storage and Transportation
Once the coil is wound, it must be removed from the mandrel, moved to storage, stored, and transported. Large, basic coil producers and processors generally have automated handling systems, coil cars, and conveyors. These units remove the coil from the mandrel and transfer it to a station, where more traditional equipment, such as C-hooks, ram trucks, and coil tongs, are used to move the coil.

Various flat pads or cushions may be attached to the coil contact areas. These are usually made of rubber, polyurethane, plastic, or some other material that is softer than metal.

When the coil is removed from the conveyor, forklift/ram trucks, C-hooks, or tongs are usually used to transport the metal. These devices can damage the coil’s edges. One mishap, such as a bump, can severely damage the entire edge of the coil. The only way to correct this damage is to slit the coil to a narrower width. However, this requires additional processing and wastes material. This waste can be substantial, depending on the amount of trim required to reach the next usable coil width.

The best method of protecting the metal during these operations is to cushion the areas contacting the coil, such as the sides and the back sides of the transport devices.

When coils are stored, stacking is not recommended. However, when space limitations make stacking a must, coils should be stored not more than three high because the weight on the bottom coil can deform it and make it square. This usually renders the deformed coil scrap.
Prepainted, coated, polished, or soft metals may need further protection when stored.
Coils can be stored in pads or racks when floors are wet, dirty, debris-covered, uneven. These devices isolate the coils from the floor and help prevent damage caused by hard set-down or placing coils on debris (which can dent the material).

Cost of Quality
Whenever and wherever coils are handled, damage can occur. Incurring or repairing damage, either at a vendor’s facility or at a tube mill, adds cost and compromises quality.
When reviewing processes or auditing suppliers, tube manufacturers should consider these problems and their simple resolutions. Excess cost anywhere in the supply chain adversely affects everyone’s bottom line.

Al DiZanni is a Field Sales Engineer specializing in steel handling and steel processing from Kastalon, Inc., 4100 W. 124th Place, Alsip, Illinois 60803, phone 708-389-2210, fax 709-389-0432, Website: www.kastalon.com

Kastalon is a manufacturer of polyurethane coil storage, handling, and protection products.
This article originally appeared in an issue of TPJ, a FMA Communications, Inc publication.

Filler Plates – Cargill Steel

Challenge/Problem/Issue
As the global demand continues to grow for light gauge metals in the automotive, appliance and building material markets, the metal coil processors must adapt to the unique challenges of producing surface-sensitive materials.

Because the pre-finished metal surface is more susceptible to scratches or damage, they must pay extra attention to the equipment and the handling of the coils.

Solution
Cargill Steel, East Chicago addressed their desire to successfully process light gauge materials by purchasing a new re-coiler reel for this application. Unfortunately, they continued to experience creasing, “head-in” damage, and marks on their finished product. They made several process changes as well as modifications to the reel but could not obtain an end product that they believed would be acceptable to the market that they were trying to attract. As a result, they moved away from those customers.

Cargill Steel started investigating ways to eliminate the damage they were experiencing and sought the assistance of Kastalon Polyurethane Products , who are well known for their coil protection solutions. After many months of design and engineering reviews, Kastalon made the recommendation to outfit the reel with a multi-segment bolt-on set of engineered polyurethane filler plates.

Once the filler plates were installed and put into service, several different gauges were run. The first was a .070/.071 thickness. This coil ran twice through the line and re-coiled twice on the filler plates. No markings could be felt. The second coil run was considered light gauge at .017 thickness. This coil also ran through the line and re-coiled twice on the filler plates. Again, the Quality Control Supervisor reported no marks.

Customer Value

The success of these coils has since allowed Cargill Steel to go after the light gauge market. In addition to the added business opportunity, the Kastalon Polyurethane Filler Plates are far lighter than steel, thereby allowing for faster change-outs and reduced maintenance costs have further improved operating efficiency.

Expanding Mandrel Sleeves – Titan Steel

Challenge/Problem/Issue –
Titan Steel was not satisfied with the scrap rate they were experiencing on the coil processing lines and wanted to find a way to maximize their output.

As one of the worlds largest distributors of tinmill and an important distributor of steel plate including pressure vessel plate, hot and cold rolled steel, coated steel products including galvanized steel and prepainted steel, efficiency are extremely important.

Solution
Kastalon engineered expanding mandrel sleeves made from specifically formulated Kastalon Polyurethane® with exceptional wear properties and expansion capabilities. The mandrel sleeve not only increased the diameter of the mandrel but significantly reduced the damage and reduced the manpower required for change-outs.

Customer Value
According to the Plant Manager, “Kastalon’s Expanding Mandrel Sleeves virtually paid for themselves the moment we unwound our first coil. With coil prices at a premium, every effort to maximize our output must be made and we look to Kastalon to help design products such as Mandrel Sleeves. An initial investment on our part has optimized our production, giving our customers an excellent finished product while maximizing our operating profits.”

Running 180,000lbs per day, Titan Steel calculated a yield of 50-75 more sheet-per-coil on their blanking line using Kastalon’s Expanded Mandrel Sleeves. At a estimated cost of $2.00 per sheet, that represents a savings of $800-1000 per day, which does not include the huge cost savings in the manpower required to scrap the previously damaged sheets.

Kastalon Crane Bumpers – Simple and High Performance Can Be One and the Same

For more than 40 years, Kastalon supplies crane bumpers into every imaginable environment around the world.

From ports and shipyards to steel mills and industrial facilities, Kastalon bumpers are unaffected by extreme environmental conditions, and are highly effective in temperature extremes from less than -51°C (-60°F) to 107°C (225°F).

Approved for use on nuclear fueling cranes by the U.S. Navy and for nuclear power house cranes, Kastalon crane bumpers are virtually unaffected by gamma ray exposures in excess of 1×109 Roentgens.

Whether you are purchasing new equipment or are replacing existing bumpers, specify Kastalon Crane Bumpers.

To assist you in sizing or customizing bumpers, Kastalon offers an interactive web site for calculating the exact bumpers to meet any requirements.

Access the Kastalon Crane Bumper Calculator by visiting www.kastalon.com or contact us directly and an applications engineer will help select your optimum bumper.