Tesla Motors aluminum process and assembly for their Model S

We are proud to be just a small part of the Tesla Motors aluminum process and assembly for their Model S, located in California. The Tesla aluminum coils weigh up to 20,000 lbs and rest easily on Kastalon’s yellow Coil Floor Storage Pads. The assembly shop found that if they create production staging areas near their lathes, they are able to protect the working surface of the aluminum rolls while they wait to be a bigger part of the automotive production.

At Kastalon, we specialize in finding effective solutions that will improve yield, quality and production efficiencies, literally from the ground up. As a roller shop keeps evolving, they are finding that at times their racks are full during production and they have nowhere to set their large steel work rolls, backup rolls or roughing rolls. That’s when Kastalon’s Coil Floor Pads come into use.

Made of bright safety yellow polyurethane, the patented deep cradle fits virtually any size roll and takes up nominal floor space. The unique design offers the versatility of using it as a movable fixture in staging areas or affixed permanently to the storage area floor.

Contact a Kastalon Sales Representative today!

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.”

 

Slitter Spacers and Slitter Tires

Kastalon’s slitter spacers and slitter tires are the perfect products for precision metal coil slitting. More lightweight and durable than alternatives on the marketplace, Kastalon’s slitter components resist fatigue, resist cracking, are non-marking, and are easily customizable.

Contact a Sales Representative Today!

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.

Introducing Roll Shop Bonnets

A roll shop in an Indiana mill has coined these Bonnets. They have been using these parts for over 10 years and now have completely replaced all of their metal bonnets with polyurethane.

Roll Shop Bonnet Benefits:

  • Self-sealing polyurethane eliminates the need for a rubber gasket.
  • The polyurethane is resilient and holds its shape in the event of an impact during loading/unloading of the roll package into the mill. The dented and bent steel bonnets are a thing of the past.
  • Polyurethane is 70% lighter than steel. The mill has eliminated the use of a jib crane to bolt the polyurethane ones into place.
  • Due to the non-stick aspect of polyurethane, there is significantly less effort required removing the excess grease from the I.D.

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!

Polyurethane Protects Arresting Wires and Pilots, Too

The CVN 78 Gerald Ford aircraft carrier is often seen as the most technologically advanced in the U.S. Navy’s fleet. And part of that technology includes new polyurethane-covered plates from Kastalon that help absorb the impact of arresting cables as they are dragged across the deck.

When a fighter jet lands on an aircraft carrier, it’s still traveling at up to 150 miles per hour — with 500 feet or less in which to stop. So, the plane has a special tailhook that grabs one of several arresting wires stretched across the deck in order to transfer the energy and slow the plane to a halt quickly.

The arresting wires take quite a beating as they repeatedly drag across the deck with enough speed to make sparks fly. Enter Kastalon’s polyurethane-covered plates. The plates help to absorb the initial impact as the wire hits to protect it from damage and failure, which in turn helps protect the fighter jet and its pilot.


Originally reported by http://incrediblepolyurethane.com

Miliary

Polyurethane covered plates absorb the force of the initial impact on flight deck

Kastalon’s polyurethane covered plates help absorb the initial impact of the cable assembly on the flight deck, of the new aircraft carrier, the CVN 78 Gerald Ford.

Kastalon is proud to be a Department of Defense (DOD) sub-contractor for the new aircraft carrier, the CVN 78 Gerald Ford. Not only is the Ford class aircraft carrier the most powerful ship in the world, it’s technology is the most advanced in the entire fleet. If you look at time frames 2:10 through 2:27, you will see 3 angled areas on the deck just after the arresting cable. These are polyurethane covered plates that absorb the initial impact of the cable assembly with the flight deck. To get an idea of the forces and nature of the impact at 2:22 you will see sparks from the cable dragged across the deck after the polyurethane absorbed the force of the initial impact. This is incredibly brutal to the arresting wire equipment. Without the protection provided by the pads the arresting wire would be compromised which could result in failure and the loss of the aircraft, perhaps the pilot as well.

During the ship’s Independent Steaming Exercises (ISE), USS Gerald R. Ford’s crew tested and evaluated the ship’s capabilities, including 83 aircraft launches and recoveries. For these flight operations, the new launch and recovery technologies, Electromagnetic Aircraft Launch System (EMALS) and the Advanced Arresting Gear (AAG), were on display.

CLICK IMAGES TO ENLARGE

We are very proud of the fact that Kastalon worked with Navel Engineering to develop the design and is the only manufacturer qualified to supply these pads. Kastalon’s parts and products are in nuclear submarines, mining, heavy equipment, material handling systems, steel and metals manufacturing and processing, converting, food, packaging, aircraft, and even on the space shuttle and space station. From deep sea to deep space, Kastalon manufactures the most innovative, highest quality polyurethane components for military, industrial and commercial equipment systems.


About ACIBC
The Aircraft Carrier Industrial Base Coalition (ACIBC) represents businesses that supply parts, equipment and services for the construction and maintenance of U.S. Navy aircraft carriers. Established in 2004, ACIBC seeks to preserve the strength of the aircraft carrier force and promote the value of the aircraft carrier industrial base as a vital part of the nation’s overall defense structure.

Source: US Navy. Originally reported by ACIBC (The Aircraft Carrier Industrial Base Coalition). Photo Credit: US Navy/Erik Hildebrandt
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Hurricane Assistance comes in all shapes and sizes

“Having a knowledgeable sales person that could evaluate the situation and develop a strategic plan to efficiently process the roller allowed Berry to reduce the down time and continue to support their customers.”

Due to Hurricane Harvey’s  damage sustained at the Berry Plastics facility in Victoria, Texas, the Berry Plastics plant in Aurora, Illinois was called on to ramp up their operations to pick up the production lost in Texas. In order to keep running, Tim Neal, the Purchasing Agent at Berry Plastics in Aurora, reached out to Kastalon Inc. for emergency assistance on a roller that had imperfections and that needed regrinding.

Thanks to the technical expertise of the sales engineer at Kastalon, the roller was inspected at the Berry facility and sent to Kastalon for emergency repairs and an expedited return. According to Tim Neal, “Having a knowledgeable sales person that could evaluate the situation and develop a strategic plan to efficiently process the roller allowed Berry to reduce the down time and continue to support their customers.” When faced with critical disasters, it is imperative to have suppliers that not only have the expertise and ability to help, but the compassion to help where they can.

Kastalon offers complete roller services from the simple recovering of used rollers to regrinds, core repair, bearing assembly, balancing, and new core construction. We can work from samples, drawings or provide design and engineering assistance to develop the most effective solution. Learn more about our Roller Covering Solutions today!


Berry Plastics, is a global leader in packaging and protection solutions. They believe we have a responsibility to play a positive role in the communities and environments in which we operate and serve. From the way we operate our facilities, to the industry partnerships we have developed, to our community education programs, Berry is committed to designing our products with the environment in mind.

Hurricane Harvey – August 25-29, 2017

Polyurethane Gib Blocks vs. Babbitt Gib Blocks

Location: 84” Hot Mill Roll Shop
Originally reported:
April 3, 2009

At the 84″ Hot Mill Roll Shop, the Area Manager and his team were experiencing a short life span of three to four weeks from their Gib Blocks that had standard Babbitt material on their Herkules Roll Grinder. The Gib Blocks in question measured 5.118” diameter by 2.717” in overall height and 6.69” diameter and 3.11” in over all height. Two of each is required at time on this machine. Kastalon looking to always come up with a way to ease our clients pain, suggested replacing the standard Babbitt material used throughout the industry for this application, with our specially formulated polyurethane material. The roll shop has now been using Kastalon’s polyurethane Gib Blocks for over a year now with great success. The polyurethane Gib Blocks are lasting four to five times (12 to 16 week life span) longer than the Babbitt material Gib Blocks. Putting a cost savings number to this is as follows.

Due to this mill’s purchasing standards, the area manager was unable to tell us what they were paying for the Gib Blocks to be reconditioned with the Babbitt material, but they did gave us permission to quote him on saying “Kastalon’s material costs substantially less”

The price of the Gib Block reconditioned from Kastalon is as follows:
5.118″ diameter by 2.717” overall height $190.00 ea
6.69″ diameter by 3.11 overall height $225.00 ea
The machine uses two of each at a time for a total of $830.00

$830.00 x 15 times per year with Babbitt material equals $12,450.00
$830.00 x 4 times per year with Kastalon’s Polyurethane equals $3320.00
Savings per year to the mill: $9130.00

Using Kastalon Prices, with the substantial longer life cycle of the Kastalon Gib Blocks, we can show a savings to the mill of $9130.00 per year for one roll grinder. We have now moved passed the testing period and we are outfitting the rest of the grinders with the Kastalon Gib Blocks at the 84″ Roll shop.
In addition, weigh inventory costs, transportation costs, labor costs.