COMPELLING ADVANTAGES FOR COIL PROCESSORS

A Cut-to-Length coil processing line is a big investment. The rate of return is based on  efficiency – how much product it runs in a given period of time – and on the quality of the product it produces.

Service centers and toll processors tend to buy ‘specialized’ CTL lines: anything from light gauge lines for surface sensitive products to heavy lines that level coiled plate. Specialized lines can provide competitive advantage for serving a niche market, but they may be inefficient (or just not capable) of running other products. Yes, that heavy duty line for coiled plate can also run light gauge . . .  it’s just going to run it very slowly.

The Temper Stretch™ Cut-to-Length Line lets you produce a broad range of premium quality products to serve several markets AND run each of them at top speed. It operates more efficiently and enjoys a higher rate of return than conventional CTL lines. In other words, the Temper Stretch Cut-to-Length Line ‘stretches’ your capital investment to cover more market, more efficiently.

Versatility

The Temper Stretch™ CTL Line incorporates the best tools to get both heavy and light gauge material flat enough to satisfy the industry’s tightest tolerances. It can run both heavy and light gauge with virtually no changeover, and runs all thicknesses very efficiently at top attainable speeds. It provides a cold reduced surface on light gauge material (where it’s more important), and also masks coil breaks on light gauges (where coils breaks are more prominent).

Higher Efficiency

With the wide product range it can handle, the Temper Stretch CTL Line would always be running.  But more importantly, it would always be running at top speed for the type of product being produced – up to 84 meters/min. for lighter gauges, whereas a heavy gauge Stretcher Leveler only line runs light gauge material at 30 – 35 meters/min. These factors combine for higher overall efficiency and fast payback for Temper Stretch CTL.

Premium Product Quality

It’s not enough for sheets to look flat, they must remain flat after cutting, shearing, punching, etc., and demand for this ‘premium’ product is growing. The Compact Temper Mill and Stretcher Leveler deliver stay-flat sheets cross a wide range of thickness, plus a premium temper passed surface on lighter gauges and removal of coil breaks. The ability to hold +/-0.15 mm length tolerance is another quality advantage few other CTL systems can offer.

Lower Capital Cost

The cost of a Temper Stretch CTL Line is 25% less than a  CTL line built around a traditional large temper mill. And the Temper Stretch CTL Line handles a product range that might otherwise occupy multiple conventional CTL lines, so it represents a potentially even bigger savings in overall equipment cost and in building space.

Lower Operating Cost

If one Temper Stretch CTL Line  replaces 2 conventional CTL lines, you’ll need fewer operators and material handlers and enjoy lower utilities expense. Maintenance expenses will also be less, and not just because there are fewer pieces of equipment. The Compact Temper Mill and Stretcher Leveler entail less maintenance than a large Temper Mill, and the fixed shear is much more reliable than an alternative rotary shear.

COMPARE PRICE, PERFORMANCE AND
CAPABILITY

The table below provides a side-by-side comparison of a Temper Stretch CTL line with a Stretcher Leveler CTL line and a traditional (large) Temper Pass CTL line. The values are based on lines capable of processing 1.9 to 12.7 mm (14 gauge to 1/2″) thick by 1829 mm (72″) wide material.

 Stretcher Leveler CTL LineTemper Pass CTL LineTemper Stretch CTL Lne
     Speed for 1.9 mm (14 gauge) Material36.5 mpm (120 fpm) using stretcher
in loop mode
55 mpm (180 fpm) using temper mill
many mills don't process material < 3mm
61 mpm (200 fpm) using small temper mill
in loop mode
     Speed for 12.7 mm (1/2") Material24.4 mpm (80 fpm) using stretcher
speed not as important for thick material
45.7 mpm (150 fpm) using temper mill
speed not as important for thick material
24.4 mpm (80 fpm) using stretcher
speed not as important for thick material
     Length Tolerance for 3.4 mm
     (10 gauge) Material
±0.25mm (±0.010") using loop mode
fixed shear provides close tolerances
±1.6mm (±0.062") with rotary shear
rotary shear provides inferior tolerances
±0.25mm (±0.010") using loop mode
fixed shear provides close tolerances
     Length Tolerance for 12.7 mm
     (1/2") Material
±0.79mm (±0.031") using start-stop mode
fixed shear provides close tolerances
±1.6mm (±0.062") with rotary shear
rotary shear provides inferior tolerances
±0.79mm (±0.031") using start-stop mode
fixed shear provides close tolerances
     Cold Reduced Surface FinishNo
has no temper mill
Yes**
on both thin and thick material
Yes
for thin material where surface look is important
     Mask Coil BreaksNo
has no temper mill
Yes**
using temper mill
Yes
using temper mill
     Shape Performance on Thin MaterialVery Good
using stretcher leveler
Good**
using temper mill
Excellent
using stretcher leveler + possibly temper mill
     Shape Performance on Thick MaterialExcellent
using stretcher leveler
Good
using temper mill
Excellent
using stretcher leveler
     Level of Maintenance RequiredExcellent
due to stretcher leveler and fixed shear
High
due to big temper mill and rotary shear
Moderate
due to small temper mill and fixed shear
     PriceExcellent – $8 Million
based on budget quote
High – $18 Million
based on actual cost
Moderate – $10.5 Million
based on budget quote

** the Temper Mill CTL line in this study did not run thickness < 3.4mm (10 gauge) because of lengthy changeover time.