Overcoming Safety Challenges and Tight Deadlines in Textile Production

A leading manufacturer of advanced textiles encountered a critical challenge in their production process. Removing a damaged 40-foot-long roll from a very tight spot in a nonwoven textile machine presented a unique and potentially hazardous situation. Given the roll’s exceptional length, it could not safely support its own weight during removal, posing a significant risk to both equipment and personnel. This complex problem required an innovative, custom-engineered solution to ensure safe and efficient operations while minimizing production downtime.

CHALLENGES

The primary challenge in this project was the safe removal of an exceptionally long, damaged roll from a very tight spot in a nonwoven textile machine. The 40-foot length of the roll presented a unique safety hazard, as it was too long to support its own weight during the removal process. This situation posed significant risks to both equipment and personnel. Standard lifting equipment was also inadequate and needed to be improved, necessitating a custom solution. The client would face potential production delays and safety concerns if a suitable method for roll removal couldn’t be devised quickly. Furthermore, any solution needed to be cost-effective and delivered within a tight timeframe to minimize disruption to the manufacturing process.

SOLUTION

CMMC addressed the challenge by designing and fabricating a custom 37-foot-long spreader beam that would fit in the tight area. This innovative solution safely distributed the weight of the 40-foot damaged roll during removal, ensuring the integrity of both the roll and the nonwoven textile machine. Our team utilized advanced custom fabrication techniques to create a beam that met the exact specifications required for this delicate operation. The custom-designed beam provided the necessary support for safe removal while offering the flexibility needed for maneuvering in the confined manufacturing space. This solution effectively balanced safety considerations with operational efficiency, allowing for smooth extraction of the damaged roll.

RESULTS

CMMC successfully delivered a 37-foot-long custom spreader beam on budget and ahead of schedule. This solution enabled the client to safely remove the damaged 40-foot roll from their nonwoven textile machine without incident or damage to the machine. The custom equipment minimized production downtime and mitigated safety risks, helping the client maintain operational continuity and avoid costly delays. By providing this tailored solution through our Custom Fabrication process, CMMC demonstrated our ability to address complex engineering challenges in the textile industry efficiently and effectively.

CMMC is your one-stop solution for industrial and manufacturing part repair and replacement. We leverage our advanced fabrication equipment and a team of highly skilled fabricators to deliver a proven track record of success, serving industrial facilities across the Southeast region of the United States. We understand the critical nature of your needs and are dedicated to providing unparalleled value. Our ISO certification ensures the highest quality standards, guaranteeing your satisfaction and success. Give us a call at 803-464-7489 or email us at info@cmmcsc.com to learn more.