SmartMedia – Pucest® protect GmbH

Optimization of concrete mixer

Our customer operates a concrete plant and uses a ring trough mixer. However, the mixing results leave more and more to be desired and the mixing time, a significant factor, is also getting longer and longer. The reason for this is worn mixing arms. These lead to a rotor encrusted with concrete.

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Lining of a flap bucket

Our customer has had a new flap bucket installed. However, the side walls are made of metal and completely unprotected against wear. We lined the bucket with PUCEST plates in 12mm and the “PUCEST round corner”. First, the bucket is measured and templates for the cuts are made. Cutting the panels and corners is possible with a jigsaw without any problems. The plates and corners are now screwed to the bucket. The perfect lining is ready.

Repair of concrete mixer

Our customer’s concrete mixer was very heavily used. The mixer floor was worn and the slide valve was no longer functional, making it almost impossible to discharge the concrete. The walls of the mixer were also heavily corroded and were originally due to be replaced. Our suggestion to simply rotate the side walls was gratefully accepted – saving a lot of money.

The PUCEST shovel with carbide edge

The patented mixing blade combines the advantages of the PUCEST material with the benefits of carbide components. This means that the products are able to absorb and flexibly avoid any impact.

The carbide flakes of the carbide carrier plate form a protective layer in particularly stressed areas and protect the blades from wear caused by abrasive mixed material.

Custom-fit spare part from PUCEST

Our customer operates a plant for the production of polymer compounds. During the production process, plastic granules are transported to the systems via a pipe system. One weak point was a transition piece from a square pipe to a round pipe with a diameter of 10 cm. The transition piece was made of metal and was regularly ground through at various points.

Pucest SZ panel in material chute

By changing the lining material from wear-resistant steel to PUCEST, the normal PUCEST plates were already able in spring 2021 to increase the service life of the lining by around 50%. When PUCEST suggested the PUCEST SZ plate as the best solution for the material chute and promised an even longer service life, we were quite skeptical. The SZ plates were installed in spring 2023.

Funnel lining with PUCEST wear protection plates

Two of our customer’s discharge funnels are completely worn out, rusted through and ground through by the mortar. Both were lined with wear-resistant steel. The small funnel was removed, welded in our workshop and lined with PUCEST plates.

Maintenance service for a twin-shaft mixer

Our customer has a twin-shaft mixer that runs continuously. Now the linings and mixing tools are quite worn and major maintenance is due. Our assembly team managed to repair the mixer with full commitment and within a very short time.

Lining of an inlet funnel

Our customer’s material feed hopper was pretty battered after a few years. Instead of a new hopper, which would have meant considerable costs and downtime, we suggested lining the hopper with PUCEST panels with a perforated plate insert.

Success Story – Mixer life saved

Wear protection for a weighing conveyor

The seals were worn and material could seep through the side guides. The side guides were made of steel and were quite damaged in places. Our assembly team used PUCEST plates and the PUCEST material guide to repair the Wiegand. A lot of drilling and screwing was now required.

Lining of a feed hopper

Our customer’s hopper was not lined. Due to the structure of the metal sheets, material residues were accumulating and solid caking was formed. We received the order to completely line the hopper to prevent major wear. We took on the task with our PUCEST panels with perforated metal inlay.

Conversion of ring trough mixer

Deprecated: preg_split(): Passing null to parameter #2 ($subject) of type string is deprecated in /mnt/web616/a0/11/52249411/htdocs/wordpress_pucest_en/wp-includes/formatting.php on line 3494 The bearings of the arms are worn out and the rotor has been damaged by concrete penetration. A repair with original parts would not only be very expensive, it would also be difficult to procure and would have very long delivery times. Our customer asked us for a quick and cost-effective solution. The solution is... Deprecated: strip_tags(): Passing null to parameter #1 ($string) of type string is deprecated in /mnt/web616/a0/11/52249411/htdocs/wordpress_pucest_en/wp-content/themes/accesspress-root-pro/inc/accesspress-functions.php on line 258

PUCEST TIX – repairing a feeder channel

Our customer operates a loading chute in the metal processing sector. A very large number of screws run over the chute. Due to high temperatures, the PU used in the outlet area has dissolved in places. In order to be able to continue operating the chute, the wear protection used would have to be replaced.

PUCEST material guidance and silo lining

At our customer’s plant, there were repeated problems during transportation on the conveyor belt. The material (mainly sand) ran under the side guide and the entire conveyor belt had to be completely cleaned at relatively short intervals. The PUCEST material guidance protects the belt and ensures an even material flow.

PUCEST head wipers for conveyor belts

The cleaning of conveyor belts is always a topical issue. Residues cause high costs due to material loss and cleaning effort. The belts, rollers and system components wear out prematurely. Efficient belt cleaning is therefore urgently required for adhering goods.

Mixer conversion and defective gearbox repaired

Our customer’s ring trough mixer was badly damaged, the gearbox was worn out and the mixing arms were corroded. It was no longer possible to adjust the mixing arms. We completely dismantled the mixer, removed the gearbox and repaired it.

PUCEST easycleaner

The success story continues. The next easycleaner is at our customer’s premises.
The easycleaner really makes work easier for the employees, the short cleaning program for in-between only takes about 1 minute, a complete cleaning only 4 minutes. A considerable time saving compared to the time-consuming cleaning previously required.

Lining of a material feed hopper

The rubber lining of the material feed hopper was damaged and there was heavy caking in several places. We removed the old lining and sanded down the hopper. The hopper was measured, templates were made and the PUCEST AHA sheets were cut to size accordingly. The PUCEST AHA (anti-adhesion plate) is particularly suitable for this application.

Ring trough mixer modification

The bearings of the arms are worn out and the rotor has been damaged by concrete penetration. A repair with original parts would not only be very expensive, it would also be difficult to procure and would have very long delivery times. Our customer asked us for a quick and cost-effective solution. The solution is... Deprecated: strip_tags(): Passing null to parameter #1 ($string) of type string is deprecated in /mnt/web616/a0/11/52249411/htdocs/wordpress_pucest_en/wp-content/themes/accesspress-root-pro/inc/accesspress-functions.php on line 258

PUCEST® pipe elbows convince

Our customer brought 2 metal pipe elbows to a consultation meeting. The elbows are used in the dust extraction system. The metal pipe elbow was worn out after 3-4 weeks of use and had to be replaced. (see picture) We have got the right solution with the PUCEST® pipe elbow. The PUCEST® pipe elbow was... Deprecated: strip_tags(): Passing null to parameter #1 ($string) of type string is deprecated in /mnt/web616/a0/11/52249411/htdocs/wordpress_pucest_en/wp-content/themes/accesspress-root-pro/inc/accesspress-functions.php on line 258

PUCEST® impact beams:

Deprecated: preg_split(): Passing null to parameter #2 ($subject) of type string is deprecated in /mnt/web616/a0/11/52249411/htdocs/wordpress_pucest_en/wp-includes/formatting.php on line 3494 PUCEST® impact beams: Cost savings with sustainable wear protection Actual situation and problems in 2015: • Use of rubber impact beams in the scrap feed hopper of a foundry with an annual throughput of approx. 25,000 tons. Feeding takes place by means of a magnetic plate at a drop height of approx. 1.50 to 2... Deprecated: strip_tags(): Passing null to parameter #1 ($string) of type string is deprecated in /mnt/web616/a0/11/52249411/htdocs/wordpress_pucest_en/wp-content/themes/accesspress-root-pro/inc/accesspress-functions.php on line 258

Success Story – Mixer´s life saved

Our current patient was a ring trough mixer with a cracked rotor and completely embedded clamping and spring elements. The customer was unable to obtain a new rotor quickly. Installing a new mixer was out of the question for reasons of time and cost. So, we took on the matter. We only had a photo... Deprecated: strip_tags(): Passing null to parameter #1 ($string) of type string is deprecated in /mnt/web616/a0/11/52249411/htdocs/wordpress_pucest_en/wp-content/themes/accesspress-root-pro/inc/accesspress-functions.php on line 258

A new EasyCleaner successfully in use

Our customer runs a ready-mix concrete plant. The pan mixer had to be cleaned regularly, especially in the summer months, due to heavy caking, which took around 1.5 hours. A final cleaning, also lasting 2 hours, was carried out at the end of work. As manual cleaning is very labor-intensive and entails enormous risks in terms of occupational safety, our customer opted for the high-pressure cleaning system – easy cleaner – from PUCEST.

PUCEST TIX – repair of a pick and place chute

Our customer operates an insertion chute in the metal processing sector. A very large number of screws run over the chute. Due to high temperatures, the PU used in the outlet area has dissolved in places.

Full lining of a feed hopper

The bulk hopper & feed hopper is fed with material by wheel loaders. The material is discharged by a belt conveyor. We received the order to completely line the hopper to prevent greater wear. We tackled the task with PUCEST panels and round corners. First, residual material was removed and the hopper was cleaned.

Long-term testing Vibrochute lining

An extension of the service life of the steel material from approx. ½ year to more than 7 years with the changeover to the material PUCEST. Once again, in this case probably disproportionately, the longevity of the material PUCEST is demonstrated. The examination of the conditions on site and the correct plate thickness and Shore hardness ensure an optimum result.

Full lining of a material chute

After using the PUCEST® lining, the caking and sticking of the material has improved considerably. The overall material flow is significantly optimized. As a result, we have been able to increase the output of the entire plant and relieve the employees, which in turn creates more time for their actual tasks.

Vibrators

In our search for alternatives that – with regard to their price-benefit ratio – generate added value for us and our customers in the long term through significantly lower maintenance and wear costs with simultaneously longer service lives, we found what we were looking for at PUCEST® protect GmbH in Elsenfeld.

Step baffle plate

All the grit from the screening plant (approx. 600,000 t/p.a.) is conveyed at 2.5 m/s, then has to be stopped in order to fall onto the trucks. Usually material pads are built up as wear protection, which is not possible here due to the mixing of grains.

System impact elements

The PUCEST® System impact beams with their individual blocks were mounted on the impact rocker bars in the customer’s own workshop. In week 01/2016, the preparation plant was started with the production cycle described above. No abnormalities could be detected during the respective shutdowns.

12 years – concrete discharge hopper

Mixer high-pressure cleaning

It is a mixer high-pressure cleaning ” Easy Cleaner” ( 3 cleaning heads ) which we have in our factory in a Pemat 2m² mixer with whirler in use.

PUCEST Pipe bend

The new original Pucest elbow has significantly improved the service life. This has saved repair, downtime, and personnel costs for maintenance. The fast and uncomplicated delivery time is praiseworthy.

Hybrid plate for conveyor troughs

The wear is minimal as seen in the photo, also the visible adhesions here loosen as already described last year with time independently. We have not had to clean this gutter until today!

Lining of a bulk bunker

The bulk material & feed hopper is getting a bit long in the tooth. In order not to have to completely replace the plant part at some point, we recommended the lining with PUCEST. First we installed PUCEST panels in 2 places for testing. After a few days the customer was convinced of the performance of our material and we received the order for the complete lining.

Cleaning of positive displacement mixer

Extremely fewer repairs, service life extension, cost saving, better faster cleaning, easy fast renewal of wear parts, better mixing intensity due to PU bottom, less caking

Faster and efficient maintenance

High performance channel liner one-piece

With the PUCEST High Performance Channels we were able to carry out the first trial linings. Since the installation approx. 1.5 years ago, the troughs have been almost wear-free until today. After only one year we decided to use these trough linings also on the other balancing troughs.

Use of PUCEST in the vibro-press process

In our vibro-press manufacturing process for the production of concrete light wells, the tops are pressed in with the help of a hardened steel top sleeve. This top sleeve, with dimensions 100 x 50 cm, has a price of 4500,00 € and must be replaced every 2 months (approx. 3000 cycles).

Lining of a concrete hopper

The concrete hopper is intended to store bulk material and transfer it to a conveyor belt. Concrete is not really suitable for abrasive materials. With the lining by PUCEST plates the construction is effectively protected against wear. The hopper with PUCEST lining has now been in use for more than 4 years and still works perfectly.

Edge protection on the hopper

The Waibel company successfully uses the wear protection solutions of the PUCEST company as edge protection on the hopper for its concrete pumps. From our own experience, the material of the company PUCEST is more resistant, more durable and remains soft despite formwork oil and does not attack the material.

PUCEST material guide

Since the PUCEST material guide has already been installed in the other ready-mix concrete plants with great satisfaction, we have again decided to use the PUCEST material guide. This is screwed to the side guide plates in the upper area due to the cast-in perforated steel plate.

PUCEST® hopper lining

Problem: rapid and high wear of the rubber lining used, which had to be replaced every 5-6 months at the latest. The rubber sheets were swollen and worn down over a large area due to the use of formwork oil and mixer protection.

Pucest plate 65shore 25mm (2mm perforated plate)

Based on the experience we have already gained, we are convinced of this material for the application. Since we also use other products from PUCEST, which also work very well, we are very satisfied with the general quality and will also use PUCEST in other applications in the future.

PUCEST step plate

PUCEST step plate test phase: one year of production is over: time to present a result. Application: Discharge distribution tower and marl hall for raw material. High abrasive load with different grain sizes, dry as well as wet 0-120mm. A result that can be seen…

PUCEST hopper in waste incineration plant

A time saving of almost 3h per day, which the staff can use for the actual tasks. Target fulfilled. After 7 months in operation, no wear is visible. The purchase of a second hopper of the same design is being considered.

PUCEST Hexagon Protector

The Pucest lining was installed on 18.09.2016, and no wear could be detected during the semi-annual inspection on 13.03.2017 and on 17.09.2017. Due to these extremely positive experiences, the Hexagon Protectors were stocked by us and installed in further plant sections where grade purity is not required. Also with positive experiences.