Metals

Whether you are producing tissue paper or steel products, proper tension control is critical to producing consistent high quality results. We are experts at both of these extremes. Quad Plus has the proven experience to assist you with the design, selection of tension zones, and controls for new machines. For existing assets, we can re-tune and optimize your system or provide major retrofits/repowering packages that extend the life of your mechanical systems. Quad Plus knows how to keep machines running while reducing downtime and changeover.

We start by evaluating and characterizing your existing products and then make recommendations to improve your operations. This may involve recalibrating controls to ensure the line is running at optimal speed while maintaining the highest levels of performance and quality possible.

The Quad Plus philosophy is high specification standards and high control standards. Our experts undergo specialized training to meet those expectations including Quad Plus techniques to understand metal processing. We have the in-depth knowledge of manufacturer settings and controls to correctly calculate tolerances and tension so the quality of the process is consistent regardless of the materials.

Quad Plus understands that machine speed and tension must be maintained when changing rolls. Our specialists have in-depth knowledge of feedback devices such as dancers, pendulums, load cells, and encoders to control the splice, speed, and tension. The result is better performance with the least amount of downtime.

This customer contacted Quad Plus with concerns about their obsolete equipment controls and a custom-made rotary shear motor, which was supplied by a company that is no longer in business. Knowing that a controller failure would result in several weeks of downtime, the customer requested a solution before trouble hit. The project was further complicated because there were no existing control programs or electrical schematics; instead, we found a proprietary and dedicated “black box” with no description of its operation. Our solution included calculating the algorithm for electronic camming functionality and integrating new drives, motors, and controls. Remote monitoring equipment was also integrated, and a safety study was performed to identify areas for improvement. Along with spares for all the new systems, the customer also received detailed documentation for future reference.

This project allowed our team to proactively prevent a catastrophic disruption to the customer’s production and update and improve their current systems. Our engineers also demonstrated their skill and ability to manually calculate necessary algorithms and then create proper documentation from scratch.

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Quad Plus offers a wide variety of services to assist you no matter where you are in the system integration lifecycle. For new builds, we offer design and project management services, for existing plants, we can make your operation run smoother and more efficient. For plants with obsolete control systems, we can assist with retrofits and upgrades. No matter your business need, we have you covered!

At Quad Plus, we understand that your priorities are efficiency and throughput. When you need the best system integrator for your metals plant, our team delivers accuracy and metal industry experience that you can rely on. Plus, our friendly support staff is always available from the earliest phases of your system integration project to years after completion.

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