-
Speed, Customer
Service and Energy Savings –
Recently, a customer contacted several flighting manufacturers with a new
application for sectional flight needed in a hurry. The customer had crudely
made parts in his machine shop to prototype a solar-powered pond aerator and
unexpectedly became deluged with orders. Falcon had samples to him for
approval before others even responded with questions or quotes. In this
application, the customer estimates that the uniformity and smoothness of
the Falcon-produced parts have resulted in 12-15% energy savings. This is
significant in the performance of his product. Imagine what Falcon quality
can do for your applications.
-
Leaning Flights
for Centrifuge Repair – A
customer needed flights with a 15degree lean to the centerline of the shaft
melding to a series of perpendicular flights on either end for repair of a
centrifuge. The distance between pitches on the OD had to remain constant.
Falcon’s engineers designed, cut, assembled and shipped flights attached
to the centrifuge barrel within a couple of days. For timely problem solving
based on years of experience, call Falcon with your unique requirements.
-
Value
Engineering – A major brewing company needed to replace several 19’-long
fabricated stainless steel screws (Vetter Spent Grain Screws) with ribbon
flighting offset from the shaft. Due to lack of accurate drawings, they sent
a used screw for Falcon to match. Falcon’s production engineers
recommended several changes, including producing the flight with
integrated spokes to strengthen the completed screw and reduce
the cost of the part. The completed screws are installed and working
well. Falcon routinely does this sort of value engineering for small and
large companies. Let us look at your screw project to see how we can help
you.
-
Design
Assistance – Four different fabricators contacted Falcon Industries,
Inc. with their individual suggestions for fabrication of a potash slowdown
chute as part of a major construction project. Working with the Project
Engineer to consider ultimate project requirements and manufacturing
capability, Falcon’s engineers helped develop the final specs and produced
flight for the chute with 72" pitch shown in the top picture at right.
Contact Falcon for your unique project needs FIRST!
-
Finishing
- Falcon is a major source of stainless screw assemblies polished to CEMA-IV
for applications in the chemical and food processing industries. Sizes have
ranged from 2-44" OD in lengths to 16 feet.
-
Material
and Length - A customer in steel wire and spring fabrication needed 24-foot
long screw assemblies of a nickel-iron-chromium alloy for conveying bars
through a 2000-degree heating furnace. Falcon developed sources for shafts
and plate in the needed length and has produced several shipments of screws
to the necessary t.i.r. with non-accumulating pitch for this application.
-
OD
Tolerances - The power industry needed screws with extremely tight OD
tolerances to prevent backfiring when feeding powdered coal into combustion
chambers at coal-fired power plants. Falcon routinely produces these 16-foot
long screws having a 12" OD with no failures.
-
Alternate
Materials - Suppliers to the automotive industry were trying to find
replacement material for feed screws to carry axle shafts through shot
peening blast cabinets. These screws had previously been supplied as
castings, replacement of which was costly and increasingly difficult to
find. Falcon developed practices to fabricate the replacement screws from
high manganese steel for wear resistance and cost savings.
-
USA
Source - Working with several customers, Falcon developed production
practices and has become a major domestic source of shaftless screw
flighting made from HSLA steel used to convey and dewater sludge-like
materials in large factories and municipal treatment facilities.
