Flat Out Performance

A global manufacturer of cup- and container-forming machines located in the Midwest was looking for opportunities in its supply chain.

One of the significant parts in its market-leading paperboard cup- and container-forming machine is the iron machine base that serves as the machine platform. For any high-speed machine precision is critical, and on this particular component flatness and assembly hole location are important for easy assembly, alignment of key components, peak operation, and long-term maintenance of the machine.

The part is cast as a single piece of grey iron weighing more than 5000 lbs. It includes many pockets and ribs for strength, which makes it a robust machine base. At over 90" long, it’s also a significant challenge to produce within the .005" flatness that’s specified. To accomplish the flatness, the large casting is both heat-treated and ground before the finish machining is performed. Previously the manufacturer had successfully coordinated the casting, heat treating, grinding, and machining with outside vendors, but it was looking for a turnkey solution that would save time and reduce costs.

The challenge appeared to be an ideal match for our integrated manufacturing and services, which provide complete, finished large cast components. Managing several operations from a single location in De Pere, Wisconsin, we provided a perfect solution for this manufacturer, which was searching for ways to reduce procurement and coordination costs.
 
Today we are the single source that supplies the casting and machines the components. With support from our partner suppliers, we provide the finished component, and the part arrives at the manufacturer fully machined and ready for assembly.