Retrofit Success
A fertilizer company was struggling to meet new quality specifications in their pesticide plant. With only 120 days to comply, they turned to A&J for a retrofit solution.
Company Background
The client is a fertilizer company operating a pesticides plant.
Issue
A customer contacted us to evaluate an existing competitor’s paddle mixer as a candidate for a rebuild to a high-performance paddle mixer. Their pesticide plant faced new quality analysis standards and the existing supplier could not provide a retrofit or a machine to meet the specification. The company had 120 days to comply or risk losing business.
Solution
We had been familiar with this company for years, meeting at several trade shows including Powder and Bulk Solids in Chicago. They invited us to review their process, and we conducted a detailed mixer rebuild analysis, including on-site inspections, maintenance team interviews, and mobile test mixer demonstrations.
Back at our office, we evaluated stress calculations and torque requirements, confirming the mixer was a good candidate for retrofit. The customer purchased our rebuild kit, including:
- Custom-designed High Performance paddles and rotor arrangement
- UHMW liner for the trough bottom
- Hinged and clamped side access doors
- New high-performance drive belt and sheave
- New rotor shaft packing gland seals
We also supervised installation with their maintenance team. The rebuild was completed in 3 days.
Results:
The customer’s retrofitted machine was approved and validated immediately, securing their contract. In addition to meeting quality standards, mixing time was reduced by 50%, delivering a 3-month ROI.
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