Category Archives: Success Stories

extendable conveyor material handling equipment efficiency

Our conveyors boost productivity

Our goal as a material handling equipment manufacturer is to help our clients make their processes more efficient. How do you measure that? Well, the proof is in the numbers.

An engineering company that designs and manufactures steel automotive parts, came to us for conveyor help. We built them some customized powered extendable conveyor and roller conveyors, which were installed in October.

Since installation, our client’s Overall Equipment Effectiveness (OEE), which calculates how a machine is expected to run versus how it actually does run, for their machinery has improved by 25 percent, reporting over 95 percent OEE in November.

Our customers were thrilled with the improvements, saying their operators don’t spend nearly as much time fighting with the machinery.

Running two jobs used to take 3 hours, Process Engineer Seth Monroe said, now it only takes 1.5 hours. That’s a 50 percent improvement.

Maintenance has also become easier. Replacing the belts on the extendable conveyors used to take two to three hours. Now it takes 30 minutes.

“It takes longer to get the belts out of the crib than it does to replace them,” Monroe said.

That’s the kind of news we like to hear.

Tuff Transfer Cart is an automated space saving solution

Production facility floor space is sacred. The more organized and compact you are, the more efficient your production practices are.

Our customer wanted to crowd more conveyor into their existing space to optimize their production facility. Continuing to drive lift trucks through such a tightly packed space would increase the risk for damaged product and equipment. So our customer needed something to facilitate the movement of their product within this tight space while limiting the use of lift trucks. Tuff Automation worked together with Savant Automation to create a transfer cart that would solve their problems.

We constructed the transfer cart with heavy structural steel and laser-cut and formed components. It traveled along a rail embedded in the facility floor, which meant that lift trucks could still be driven in the same space as needed. The cart used an overhead power system, taking up the least amount of space necessary to move products from destination to destination.

The transfer cart had to carry five different products from their respective fill systems to one of two stations—a stretch wrapper or a conveyor that sent them straight to the warehouse. Check out our video of the system in motion:

The final product ended up being an excellent solution to the customer’s needs, getting the job done without trying to squeeze lift trucks through tight spaces.

The transfer cart solution can be used and customized for a number of applications. Contact us to learn more about this system.

When old equipment just isn’t cutting it anymore

tuff automation cummins engine

Even the best equipment doesn’t last forever. Whether your process changes as your business grows, or you’ve simply used your equipment to the point of breaking down, eventually you’re going to need an upgrade. Tuff Automation can help with that.

Engine manufacturer Cummins found themselves in need of just such an upgrade. Their 20-year-old equipment was no longer meeting the task of moving their product.

“[Our equipment] was never upgraded to handle a heavier product,” said Cummins Mechanical Engineer Michael McLaughlin.

So they contacted Tuff, and we worked together over a long and changing schedule to design, build, and install brand new equipment

Our design

The sum of what we worked together to create included heavy-duty CDLR with 3.5″ diameter rollers, drip pans, custom frames, and guiding. These were much better equipped to move the heavier goods. We also mounted some new CDLR on a lift table the customer provided. In addition to the CDLR, Tuff also built a walkway and railing around the conveyor, mounted spring-loaded steps on the sides of the conveyor, and replaced the sensors on their equipment.

A long and challenging installation schedule

Over the course of four weekends in February, Cummins and Tuff worked together around an extremely demanding production schedule to put the new equipment in place. Tuff Mechanical Engineer Tony Truong traveled to the Cummins facility in New York to work with a team to facilitate the installation.

“Working with Tony Truong was the best part about using Tuff,” said McLaughlin. “Not only was he great on the engineering side, offering solutions to all of our requests, he was a one-man installation crew.”

Flexibility is the key

Even when brevity is out of the question, efficiency is of utmost importance. Though the circumstances made for a difficult schedule and an ultimately longer project process, Tuff and Cummins both exercised flexibility to ensure a satisfactory product.

Building a Slat Conveyor

slat conveyor bastian solutions axels material handling

We frequently work with Bastian Solutions to engineer top-quality solutions to whatever they throw at us. One of our recent projects was a slat conveyor that carries hefty axles.

The project

The conveyor is part of an assembly line. It moves multiple axles, the heaviest of which can weigh 1600 pounds, down the line as operators gradually add components. This rugged conveyor is equipped to carry massively heavy loads in an industrial environment. It also comes with a touch screen interface to customize conveyor operation, track units through each production cell, and identify any conveyor faults.

What we did to ensure the best product

As with many of the projects we encounter, Bastian Solutions needed this solution to be of the highest quality and completed under a compressed timeline. During the processes of engineering and construction, we were able to assist Bastian Solutions in making performance-enhancing recommendations. We also facilitated a complete run-off/buy-off on our shop floor. All of this was to make sure Bastian Solutions knew we made them a product they could be confident in to do the work they needed it to do.

The final result

In the end, Bastian Solutions received a top-quality conveyor complete with integrated controls. Want a closer look at the process of construction and see the final product in motion? Check out our video below. Be sure to watch it in high quality!

At the last minute, Cisco-Eagle finds quick, reliable service to finish off their multi-million dollar project

Material handling equipment provider Cisco-Eagle was in the final stages of installing a massive addition to their original equipment for Cargill Meat Solutions, a leading meat processing facility located in Friona, TX, when they realized they needed a blade stop at the last minute. Their deadline was approaching; Cisco-Eagle knew they needed quality equipment and needed it quickly.

Pressed for time, Cisco-Eagle needed to be efficient in as many ways as possible. Production, delivery, and integration with the existing Hytrol equipment all had to move quickly. Knowing Hytrol has a tendency for longer lead times, Cisco-Eagle’s Director of Project Management Darrell Griffin contacted Tuff Automation’s sales engineer, Mark Zauel.

“Mark said he could provide equipment in a week, and it would hook up to the existing Hytrol equipment, which would save us considerable time in the field trying to make it fit,” said Griffin.

blade stop Tuff Automation material handling conveyor component custom Cisco-Eagle Cargill Meat Solutions
Example of a Tuff Automation Blade Stop

This wasn’t the first time Griffin worked with Tuff Automation, so he was confident in his decision to use Tuff Automation. Cisco-Eagle began working with Tuff when they were quoting another integration partner on a different project. While they looked through the pictures the integration partner provided with the quote, they noticed Tuff Automation stickers on some of the equipment in the photographs. After scrutinizing the photographs and hunting down Tuff Automation, Cisco-Eagle was ultimately won over by Tuff’s lower prices and completely custom solutions.

“Tuff doesn’t sell canned solutions,” said Griffin. “Everything is engineered to some extent—everything [Tuff] provides is rated to handle the load of the application.”

That initial impression was followed by years of solutions completely customized to fit their applications, which continually proved Tuff’s reliably fast turnaround and durable product construction. These experiences informed Griffin’s decision to go with Tuff for the blade stop solution.

“We have a lot of faith in [Tuff],” said Griffin.

Tuff Automation delivered the blade stop to Cargill Meat Solutions within a week’s time. The equipment integrated easily with the existing Hytrol conveyors and was durable enough for 110-pound cases of beef it needed to handle.

Quick turnaround, affordable prices, and reliable equipment are of paramount importance for those in the material handling industry, especially at the last minute. For Cisco-Eagle, Tuff Automation was able to provide all of the above, leaving all parties satisfied.