Precision Flange reduces laser outsourcing by 80% with HPR400XD

Company: Precision Flange and Machine

Precision Flange and Machine, Inc., located in Houston, Texas, specializes in precision machined and manufactured products in carbon steel, stainless steel, and alloys for the gas and oil industries. Their list of specialty products ranges from figure 8 blinds, paddle blinds and spacers to bleed rings, cushion tees, stub ends, crosses, laterals, and wyes. Precision Flange and Machine has been manufacturing since 1989, with a continual focus on producing high-quality products with minimal lead-times in a customer-friendly atmosphere.

Challenge: Production demands required expensive outsourcing

Production demands from a growing customer base were pushing Precision Flange and Machine’s oxyfuel cutting process and Hypertherm MAX200 beyond capacity. The company had to rely on expensive outsourcing for laser cutting products with fine-feature requirements. The increased workload and overtime needed to sustain the continual drive for improved cut quality, minimized secondary operations, and productivity were straining Precision Flange and Machine’s successful one-shift-per-day business model. The company needed significantly faster cutting speeds with more precision on a broader range of material thicknesses to keep pace with increased customer demand.

Solution: HPR400XD adds funtionality, relieves stress on older systems 

Mike Allen, Precision Flange and Machine’s president, leveraged his 30-year relationship with his authorized Hypertherm table manufacturer for help with the technology upgrade. Initially interested in rebuilding his existing cutting machine, Mike chose to purchase a new machine with enhanced motion capabilities and upgrade his cutting operation with a HyPerformance® Plasma HPR400XD® and ArcGlide Torch Height Control.

This combination of precise table motion with HyDefinition plasma cut quality and ArcGlide’s productivity improvements would augment Precision Flange and Machine’s existing product offering with multiple new thicknesses of parts to be cut on the same table. Additionally, the new system would relieve some of the cutting done by the company’s older PAC500 with three 601 power supplies, and operating costs would be lowered by maximizing production speed and consumable life.

The HPR400XD

HyPerformance plasma systems deliver superior productivity in X-Y, bevel, marking, and robotic cutting applications on metal ranging up to 160 mm (6.25 inches) thick. The combination of faster cutting speeds, rapid process cycling, quick changeovers, and high reliability dramatically lowers operating costs while boosting overall performance, productivity, and profitability. HyPerformance plasma systems deliver the ultimate in HyPerformance mild steel cutting, plus aluminum capability, and unmatched stainless steel cut quality. The HPR400XD and HPR800XD are the best suited plasma systems for cutting thick materials including mild steel, stainless steel, and aluminum.

Patented PowerPierce® technology, combined with a controlled motion process, extends production pierce capability. The HyPerformance HPR400XD is capable of piercing and cutting mild steel up to 50 mm (2 inches) thick and cutting mild steel up to 80 mm (3.2 inches) when starting on an edge. At 400 amps, the HPR400XD can pierce and cut stainless steel up to 45 mm (1.75 inches) thick and cut stainless steel up to 80 mm (3.2 inches) when starting on an edge. The HPR400XD can pierce and cut aluminum up to 40 mm (1.5 inches) thick and cut aluminum up to 80 mm (3.2 inches) when starting on an edge.

Benefits of using the HyPerformance Plasma HPR400XD include:

• Superior cut quality and consistency

  • HyPerformance plasma cuts fine-feature parts with superior quality and consistency.

  • HyDefinition technology aligns and focuses the plasma arc for more powerful precision cutting up to 80 mm (3.2 inches).

  • New HDi™ technology delivers HyDefinition cut quality on thin stainless steel, with extremely sharp top edge quality, shiny surface finish, and superior angularity with reduced angle variation.

  • The HPR400XD cuts, bevels, and marks carbon steel, stainless steel, aluminum, and other metals with HyDefinition precision.

• Minimized operating cost

  • HPR technology significantly increases consumable life and enables consistent HyDefinition cut quality.

  • Faster cutting speeds deliver more parts per hour.

  • Higher quality cutting virtually eliminates the cost of secondary operations.

  • Patented PowerPierce technology can pierce thicker materials than ever before and replaces slower-cutting oxyfuel technology.

Busines impact: Improved cut quality, productivity, and consistency

Precision Flange and Machine realized immediate benefits from the HPR400XD upgrade, including a significant improvement to cutting speed and quality. The HPR400XD delivers consistent cutting performance that requires almost no cleanup, enabling Precision Flange and Machinery to eliminate production steps from the cutting process.

 “From one piece to 100 you get the same quality cut with almost no cleanup to speak of, so we have been able to eliminate other production steps. Our operator can take a lunch break and come back to the system still cutting quality parts.” – Mike Allen, President, Precision Flange and Machine

Other benefits include a 30% productivity improvement and the ability to bring more work back in-house for tighter quality control and lower costs. The HPR400XD can replace laser cutting for most applications, enabling Precision Flange and Machine to reduce outsourcing laser cutting by 80%.

Switching between jobs and materials is easy with the HPR400XD, so Precision Flange and Machine has significantly reduced downtime between jobs. The ability to instantly switch from gauge material to 2.5 inch stainless, in addition to the cut‑to‑cut cycle time enhancements of the ArcGlide, have enabled a more aggressive pursuit of new customers.

As Precision Flange and Machine prepares for future growth with the purchase of a HyPerformance Plasma HPR800XD, Mike feels the investment in Hypertherm technology products has been proven as a critical element of Precision Flange and Machine’s success.

“If you spoil your customers, they’ll continue to come back to you.” – Mike Allen, President at Precision Flange and Machine

Learn how the HPR400XD can help your business strike the perfect balance between cut quality, cut speed, and cost. Click the button below, fill out the form, and a Hypertherm product expert will contact you.

Contact an expert