Page 21 - MetalForming April 2017

process efficiency and part-to-part repeatability.
In production since January of this year, the new hydraulic press primarily forms 1⁄8-in-thick extruded aluminum to produce multiple versions of rafter squares that range in size on either side of 1 ft. long. Weekly volumes range from 3000 to 25,000 parts depending on the model number, according to Lallensack.
Hydraulic the Best Option for Empire
Well-known characteristics of hydraulic presses—dwell time and stroke-speed control—made this type of machine the best option for Empire Level.
“We looked at servo, mechanical and hydraulic presses,” recalls Lallen- sack. “A hydraulic press gives us the control ability of the servo, and the ability to gain the tonnage and dwell that we need. The press became the best of all worlds for us, especially given the added dwell time so important for the coining process.”
The new press indeed has provided the reliability and productivity that Empire Level had sought, and the com- pany continues to make headway in reliability in other areas, including the press tooling. Empire Level contracts with local companies for tool build and significant maintenance, while per- forming preventive and more routine maintenance inhouse.
“We are on the journey now toward proactive tool and machine mainte- nance,” offers Lallensack. “We have been implementing maintenance soft- ware as well as products and processes to track our equipment assets and ramp up our preventive- and predic- tive-maintenance efforts.”
Lallensack points to the ability to have a press built exactly to its speci- fications as key in the success of the upgrade project.
“Beckwood was able to design, engi- neer and build the custom press for our specifications,” he says. “In addi- tion, its operations in St. Louis are rel- atively close to our location. Toward
the end of the build, I was on a family vacation nearby and Beckwood allowed me to come in and see progress.”
Initiatives, Acquisition Bring Growth
“We’ve been growing at a 20-percent annual clip for the past few years, and have featured the ‘Made in America’ concept at Empire Level,” Lallensack says. “That was another reason for the
press choice, as Beckwood built this press, and builds all of its others, here in the United States.”
Besides the investment in people and equipment, Lallensack also attrib- utes Empire Level’s growth to the Mil- waukee Tool acquisition, which has provided access to that company’s expansive worldwide customer base.
“This has been an exciting story for us,” he says, “no doubt about it.” MF
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