The problem looked like a brush problem
A hot dip galvanizing line was replacing brushes every 90 days. Performance varied from shift to shift and coating quality on the final strip was inconsistent. The customer asked us to look at the brushes. The brushes turned out to be one part of a larger problem.
Discovery
Felton MBC met with the customer’s team by video call to hear what operators were seeing on the floor: brushes wearing out at three months, results that changed from shift to shift, and intermittent coating quality issues on the final strip. The team reviewed line diagrams and piping schematics and scheduled a site visit.
Engineering Survey
Felton MBC performed the survey on site. The work included a full line walkdown, an analysis of consumables, and samples pulled for further testing. The survey identified five factors behind the problem, and only one involved the brush itself.
01. Filtration ran below spec
Operators were cleaning the magnetic separator less often than the line required, and iron fines in the solution measured well above the level needed for quality coating.
02. Spray headers pushed soils back into the brush
Opposing headers on either side of each brush pushed soils into the brush bite instead of flushing them out, and the self-cleaning nozzles rarely ran a flush cycle.
03. Brush footprints were inconsistent
No-load amperage varied widely from brush to brush, and individual brushes behaved unpredictably across the line.
04. Solution temperature ran below target
Temperature readings drifted below the target range, which reduced cleaning effectiveness on every cycle the line ran.
05. Operating knowledge was leaving with retirements
Experienced operators retired and took undocumented knowledge with them. The next generation of engineers and maintenance leads inherited the system without clear documentation on how to run it.
Review and plan
Felton MBC delivered a written report covering every finding. The plan had two tracks.
Track 1, engineering: clean the filtration system more frequently. Reconfigure the spray headers for proper flow at the brush bite. Set standard footprint targets based on brush construction and line conditions. Install denser MBC brushes.
Track 2, training: a Surface Finish Training Program built for this specific line, covering the operating knowledge needed to keep performance consistent across shifts.
Implementation
Felton MBC coordinated the engineering changes on site and delivered operator training built around the customer’s line rather than a generic classroom deck. The training used photos and diagrams from the customer’s own cleaning section, so operators learned on the equipment they run every day.
Results after eight months
- Brush life tripled from three months to nine
- Coating quality on the final strip improved
- Shift-to-shift performance stabilized
- Throughput improved 15% on the same line
- Brush changeouts, and the downtime that came with them, dropped sharply
“The training of new operators, and feedback from the MBC training team gave me true insight as to what was occurring in maintenance. We worked to put processes in place to increase job frequency, resulting in a 15% throughput of product. The exercise was well worth the investment, and the staff at MBC were very professional and knowledgeable.”
Plant Manager, Hot Dip Galvanizing Facility