hygienic design & fabrication considerations and
TRANSCRIPT
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Hygienic Design & Fabrication Considerations and Techniques
Larry Hanson
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Fabrication Methods for Stainless Steel
• Common Methods
• Sheetmetal• Cutting, Forming, Welding, Grinding & Polishing
• Bars, Plates and Shapes• Sawing, Machining, Grinding and Polishing
• Finishing• Deburring
• Grinding and Polishing
• Passivation
• Electropolishing
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CuttingSheet metal• Shearing
• Punching
• Plasma – Arc Cutting
• Laser Cutting
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Machining
• CNC• Lathes
• Mills
• Grinding
• Routers
• Automated
• Good for low cost radii
• Integrate Shapes
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Finishing
• Grinding
• Polishing
• Electropolishing
• Passivation
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Finishing Methods
Grinding and Polishing Tools Weld Cleaning
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Chemical Treatments
• Electro polishing
• Passivation
• Pickling
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Welding Methods
GTAW (TIG)
• Slower
• Added Filler Metal
• Easier to Polish
GMAW (MIG)
• Wire Feed
• Fast and Large Bead
• Harder to Polish
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Welding Tubing
Manual
• Flexible Process
• Lower Investment
Orbital
• Uniform Process
• Setup Critical
• Precision Parts and Fit
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Cost Saving Ideas
• Reduce or Eliminate Welding and Grinding
• Understand Product Contact Surfaces and Non –Product Contact Surfaces
• Avoid Corner Welds and Corner Polishing
• Stripe Finish
• Choose best welding method
• Laser Machine Optimimum Shapes
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Stripe Finishing
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Weld Finishes
WF-4 “Free Hand Buff”
“Taped Stripe”
WF-4 “Stripe Buff”
WF-1 “As Welded” WF-7 “Ground Flush”
“Taped Stripe”
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Which is easier to fit and weld?Which is easier to Grind and Polish?
A B
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Need Stiffness and Not Full Corner Choose B
A B
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Gusset Design Options(avoid tight corner welds)
A B
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Reduce Welding with Scalped Cut out
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Welding of Scalped Cutout
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Design to avoid corner weld and finish
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CNC Laser and Arc Plasma Cutting
• Group parts to maximize material usage
• Reduces Setup Costs
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Cutout Special Shapes
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Precision Work with Laser Machine
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Setup on a Stainless Steel Fabrication Shop and Maintenance Shop• Best Practices
• Stainless Only Shop – No Carbon Steel
• Dedicated Tools for Stainless Steel
• Isolate Material Storage
• Separate Work areas and ventilation systems
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RUST
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Stainless Steel Laminated Work Benches
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Material Storage
• Separate storage rack for 304 and 316 and others
• Marking method and codes
• Testing method available
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Worktables, Pressbrake and lifting devices
• Laminate carbon steel worktables with SS
• Cover moving carts and temporary storage with to prevent iron contamination – SS, plastic, rubber wood
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Separate hands tools for cutting, grinding and polishing• Have two sets of tools in two isolated areas.
• Store in separate areas.
• Change saws, drills, cutting tools, abrasives and buffing pads if contaminated
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Training employees in special handling methods• Use dedicated tool
• Change abrasives
• Set-up welding procedures
• Certify Welders to AWS or ASME standards
• Training and refresh staff to procedures
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If you cannot have separate Shop for Stainless and Carbon Steel
• Set-up a Management Plan
• Train to Plan
• An example to a dual materals shop.
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Quality Procedures
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Stainless Steel Parts on Blue Carts(Blue paint wood plywood on steel carts)
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Carbon Steel Steel Parts on Blue Carts
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Dedicate Vibration Finishing Tanks
Red Carbon Steel Blue Stainless Steel
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Separate and Isolate SS from CS
Stainless Steel on SS Rack Carbon Steel an CS Rack
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Rubber Protector for steel dies on Press brake
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Stainless Steel Bed on Laser Cutter
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Summary
• Choose best manufacturing methods for application
• Review Design to reduce or eliminate welding
• Set-up a Stainless Steel Management Procedure
• Train Staff to Procedure
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Questions??????????????????????????????????????????????