Late in 2022 “The Monty Heat Treat News” had this story about a captive/commercial heat treater in Milwaukee, Wisconsin, USA closing down their heat treat facility in favor of outsourcing the work; “NOVEMBER 29th 2022; Captive/Commercial Heat Treater Closes Doors-Outsources Heat Treating; In Milwaukee, Wisconsin, USA we find a reasonably large Captive/Commercial heat treater by the name of Treat All Metals, a division of Regal Rexnord Corp., a manufacturer of electric motors and power transmission components headquartered in Beloit, Wisconsin. For many years Treat All offered a variety of heat treating processes including press quenching on a commercial basis and also as a service for their parent company Regal Rexnord. For unknown reasons to “The Monty Heat Treat News” the company recently decided that it made more sense to outsource the work and the end result is that the company closed down with the equipment being sold off. Part of the equipment, in particular the press quenching systems will go to a local heat treater who will take over the heat treating requirements of Regal Rexnord.”
When we mentioned this story we also said that a local heat treater would be taking over some of the work and buying the equipment in particular the press quenches. As it turns out the “Allcase” batch IQ furnaces, press quenches and related items all went to a large commercial heat treater in the area. Recently we have had a couple of stories about captive heat treaters bringing their work in house (See this item; “Why do Manufacturers Bring Heat Treatment In House-Part II”, https://themonty.com/why-do-ma
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“Wisconsin Oven is pleased to announce the shipment of one (1) Electrically Heated Horizontal Quench System to a manufacturer of products for the automotive industry. This system will be used for the solution treatment of aluminum.
The maximum temperature for this horizontal quench furnace is 1,200°F and interior chamber dimensions of 2′ wide x 2′ high x 2′ long. The system has the capacity to heat 450 pounds of aluminum parts and the steel basket within 60 minutes. Temperature uniformity of +/- 10°F at set points 850°F and 1,050°F was verified with a nine (9) point profile test prior to shipment.
This horizontal quench system provides a 15 second quench delay from when the door begins to open until the load is fully submerged in the tank. The quench is manual, where the operator pulls the load out of the oven and onto the quench elevator using a hook. The quench delay time is recorded and enforced using sensors to detect the start and end of the quench operation, and to stop the process if the quench delay time expires. Click on this link to watch a video of this system in operation.
“This Horizontal Quench System was designed with a manual quench which is a cost-effective option and still ensures there are no improperly processed parts. The system also features foldable unload wheel rails to save on floor space.”
– Doug Christiansen, Senior Application Engineer”
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ADAMSKI, Robert “Bob” J. Age 54. May 21, 2023. Beloved husband of Kim, for 25 beautiful years. Adored father of Shane and Brody. Dear son of Audrey and the late Richard. Loving brother of Gerald, Debbie (Paul) DeCook, James (Tina) and Sue (Joe) Jozwik; and brother-in-law of Amy (Paul) Giannosa and Adam (Kim) Wiley. Cherished uncle of Laura, Ann, Carol, Justin DeCook, Ashley (Ryan) Lombardo, Joshua DeCook, Andrew, Jacob, Zackery, Tyler (Sydney Kayfes) Jozwik, Cameron Jozwik, Brandon Jozwik, Leah Wiley, Lukas Wiley and Liam Wiley; and grand-uncle of Lucia Lombardo and Joanna Lombardo. Beloved son-in-law of Linda and Bobby Ray Wiley and grandson-in-law Polly Wiley. Bob had so many different hobbies and interests he loved like golfing, corn hole, jet skiing, playing pool, skiing, playing cards, arcade games & games with his family. He especially loved watching movies with his little buddy, Brody. He excelled in his profession and took pride in his work at Ford Motor Company. He was beloved by his family, and so many lifelong friends. He will be truly missed, but never forgotten. Visitation Tuesday, May 30, 2023 from 3-9pm with a 7pm Scripture Service at Wujek-Calcaterra & Sons Inc., 36900 Schoenherr Rd at Metro Parkway (16 Mile). Funeral Wednesday, May 31, 2023 Instate 10:30am until time of 11am Mass at St. Malachy Catholic Church, 14115 E 14 Mile Rd. (Btw. Schoenherr & Hayes). Please share memories with the family at their “On-Line Guestbook” @ WujekCalcaterra.com
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The Metal Treating Institute is excited to announce the Board of Trustees have approved the most progressive strategy in recent history for workforce development in the heat treating industry. This initiative, called Jobs of Tomorrow will help attract the next generation of workers to the heat treating industry. Jobs of Tomorrow is a 24-episode docu-series that plays on top streaming services, like Amazon Prime and Roku. Each season of Jobs of Tomorrow has six episodes from four different industries. Heat Treating will be one of the featured industries in the 2024 season. MTI has partnered with WorkerBee TV to develop a series of digital video assets and a distribution strategy that will be used by Members on three levels: to educate potential workers, retain current workers, and grow interest in the heattreating industry.
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May 24th the entire British Commonwealth celebrates the birthday of Queen Victoria of England. In Canada this means that Monday May 22 will be a national holiday. Regular news items from “The Monty Heat Treat News” will resume Tuesday May 22.
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“PTI Announces New Southeast HIP Facility in Alachua, Florida to Service Existing and New HIP Demand. Pressure Technology, Inc. (PTI), a leading provider of hot isostatic pressing services (HIP), announced that the company has recently completed a major expansion of their HIP services by establishing a new facility in Alachua, Florida. The new facility will provide local HIP service to its existing and new Southeast customers saving transportation costs and time. The new 12,000 sq. ft facility will initially be equipped with two of its well proven 30″ diameter HIP units with room for further capacity to be installed as demand increases. Completion of the initial phase will bring PTI’s capacity to Thirteen (13) HIP units, the majority being capable of high pressure processing up to 30,000psi at temperatures up to 2,550° F. “The expansion is in direct response to our growing customer base in the Southeast region” said David Bowles, General Manager of PTI. “Demand has been steadily increasing for the processing of parts for aerospace, space, industrial gas turbine and medical applications. In addition, the use of additive manufacturing (AM) techniques has taken hold which will further increase the demand for our hot isostatic pressing services,” he added.
The first two units in Florida became operational in 2022. In May of this year the company appointed Mr. Mark Haran Plant Manager of the Alachau location. Mark brings with him a wealth of experience in the heat treatment industry-most recently he was Production Manager at the Bodycote, Greenville, SC plant which interestingly enough is in the process of adding HIP capabilities. It is also worthwhile pointing out that Bodycote is the largest in the world when it comes to offering commercial “Hipping”.
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“In 2007, an indirectly heated roller hearth furnace (built by Wienstroth Wärmebehandlungstechnik GmbH) with energy-efficient REKUMAT® burners was put into operation at a Schaeffler plant in Germany. These burners were serviced last fall at WS Wärmeprozesstechnik GmbH in Renningen and adapted in order to be operated with both natural gas and H2 as fuel with high efficiency and lowest emissions. The successful commissioning with natural gas has already been carried out by Wienstroth. Once the hydrogen infrastructure has been established, commissioning with H2 as fuel gas will proceed.
With this and other conversions as well as newly built projects, Schaeffler is demonstrating its comprehensive commitment to sustainability while investing in the long-term future of the respective plants. Due to the decades of experience at WS Wärmeprozesstechnik GmbH with hydrogen as well as the patented FLOX® technology, the adaptation to H2 as fuel is possible for many existing plants with reasonable effort, without having to install new burners. In addition, significant efficiency gains can be realized for many plants. Until the necessary hydrogen infrastructure is available, continued operation on natural gas or mixtures of natural gas and hydrogen is possible.”
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NOXMAT USA, Inc. supplies industrial heating technology and services directly to US customers
The share of US business in NOXMAT’s total sales figures has risen steadily in recent years. Due to the continuing high demand of US customers for innovative, state-of-the-art heating solutions and burner technology “made in Germany”, the decision was made to drive further growth with a separate company for sales and service.
NOXMAT contact persons on site in the US will provide even more presence on the market and further improve customer orientation.
Zachary Spraggins becomes Business Development Manager at NOXMAT, Inc.
Zachary Spraggins joined NOXMAT USA as Business Development Manager in January 2023 and is responsible for building up the operational business. He has extensive experience in the heat treatment industry. In addition to his Master of Business Administration (MBA), he has expertise in lean manufacturing, Six Sigma, and quality management. Over the past 10 years, he has held various management positions at Bodycote Thermal Processing, most recently as Regional General Manager for the automotive sector.
“We are very pleased that we were able to win Zach Spraggins as an experienced manager for NOXMAT USA. With his extensive market and industry knowledge as well as contacts in the field of heat treatment, he will shape the development and expansion of our US business with great success”, Matthias Wolf, CEO NOXMAT, is convinced.
State-of-the-Art Heating Technology in Use all over the World
Since its foundation in 1992, NOXMAT has stood for state-of-the-art burner systems, which are developed, designed, and manufactured in-house in Oederan/Germany. Over the previous decades NOXMAT has successfully developed into a specialist for industrial heating technology. This is used in heat treatment plants of various manufacturers, including numerous US industrial furnace manufacturers. The NOXMAT product range includes recuperator and high-speed burners, control units for burner technology and radiant tubes for heating industrial furnaces. NOXMAT products are used in thermal processing plants in the heat treatment of ferrous and non-ferrous metals.
Increased Demand for Energy Efficiency and Alternative Heating Technologies
The gas heating technology mainly used in the market to date is increasingly being supplemented or replaced by electric heating and alternative heating systems, e.g. hydrogen-powered heating systems. Rising energy prices and initiatives to reduce the carbon footprint are playing an increasingly important role in retrofitting, maintaining and modernizing systems to increase their energy efficiency. For over ten years, NOXMAT has been a one-stop shop for this, from production and commissioning to preventive maintenance.
About NOXMAT
NOXMAT is a specialist for industrial heating technology, and develops, manufactures, and produces industrial gas burners as well as electric heating systems for thermal processing technology. NOXMAT’s product spectrum includes, among other things, recuperator and high-speed burners, control units for burner technology, radiant tubes for the heating of industrial furnaces, electric heating elements as well as the construction of a customer-specific switch cabinet. NOXMAT offers consulting and support for companies in over 35 countries all over the world, with great expertise and extensive service offers in the construction and optimization of heating elements for industrial thermal processing plants as well as maintenance and modernization to increase energy efficiency. NOXMAT was founded in 1992 in Oederan, Germany, and has subsidies in China, India and in the US. www.noxmat.com
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For a wide variety of reasons including higher costs, supply concerns and CO2 emissions associated with natural gas European heat treaters are continuing to look more and more at electrically heated furnaces. This interesting article originally printed by “The BMW Group” talks about an electrically heated, ring style (rotary hearth to North Americans) furnace and press quench system which recently entered production at the BMW facility in Dingolfing, Germany.
“Dingolfing, Germany May 16, 2023. For the first time, chassis and drive component production in Plant 02.10 at the BMW Group site in Dingolfing is operating an electrically heated ring hearth furnace. Compared with its conventional gas-powered equivalent, the latest electric furnace currently saves some 300 tonnes of CO2 a year.
“The new furnace has a planned service life of over 40 years, so it’s a future-focused piece of equipment that sets the course for our journey to net zero,” said Marc Sielemann, responsible for quality and production of powertrains, chassis and brakes with Purchasing, and director of the Dingolfing component plant 02.10. The BMW Group has set itself the target of being climate neutral along the entire value chain by 2050 at the latest. With its innovative power-to-heat technology, the hardening furnace came at an investment of approx. €7 million.
Plant 02.10 in Dingolfing produces chassis and drive components for BMW, MINI and Rolls-Royce vehicles. To make them more hard-wearing, the parts are hardened in special furnaces. As electric mobility ramps up, more and more components are being manufactured, including for electric drives. Existing systems are gradually reaching the limits of their capacity, so a new ring hearth furnace with a fixture hardening press was needed.
Used to harden gear wheels for electric transmissions, the innovative system has production capacity of approx. 960,000 spur gears a year. What’s special about it is that unlike the two existing furnaces, which are powered by gas, a fossil fuel, this new solution is for the first time powered by electricity. Rather than using 33 gas flames in ceramic-jacketed pipes, as the older model does, the new furnace uses the same number of electric heating elements to heat up to 900 degrees Celsius.
Electric heat generation – or power-to-heat technology, as it is called – saves vast amounts of greenhouse gases, which are harmful to the climate. By running on electricity, the new hardening oven emits approx. 300 tonnes less CO2 a year than its gas-powered equivalent.
“Energy-intensive power-to-heat systems like this new electric ring hearth furnace support the decarbonisation of heat generation – an essential aspect of climate protection. They generate heat by climate-friendly means and can be powered among other things with excess energy from renewables,” said Sielemann. So, the new power-to-heat furnace not only reduces gas consumption at Plant Dingolfing but also supports the integration of renewable energies into the electricity grid. It is another component in BMW Group Plant Dingolfing’s transformation to a sustainable BMW iFACTORY. “For the future,” said Sielemann, “we are looking into converting the remaining hardening furnaces to electricity as well.”
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Based in China furnace builder PowerMax was acquired by Fengdong back in 2017-Fengdong is in turn a mammoth Chinese furnace builder, certainly one of the largest in China.
PowerMax is currently manufacturing a batch IQ furnace, with a controlled atmosphere and oil quenching with a capacity of 4.5 tons-an astonishing 9,000 poundload. The end user is a heat treater in Turkey and the furnace was sold by a local company by the name of 3E who provides software solutions for the heat treat industry.
Over the past number of years 3E has sold almost 100 PowerMax furnaces into Turkey, customers include the largest commercial heat treater in the world, Bodycote.
This is certainly not the first furnace of this size that PowerMax has built, going back to 2010 Dale Montgomery of “The Monty Heat Treat News” inspected exactly the same size furnace at the Powermax facility in China. With her is Mr. Andy Chen the founder of Powermax.
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