Our customer’s concrete discharge hopper was completely worn out. Our customer had already dismantled the hopper and made it available. However, the basic structure was so badly damaged that we manufactured a completely new bar hopper directly on site.
The lining of the aggregate scales was heavily worn at the impact points. We removed the old material, cleaned the substrate and made templates for the new panels.
“At last we can breathe a sigh of relief! The installation of our new easycleaner is complete – and what an improvement in cleaning! I can’t believe it only took 2 days to install! That means much less effort and more efficiency for us.”
The PUCEST blow-in elbows are used for conveying fine-grained material. The conveying material collects in the honeycomb-shaped pockets, thus preventing turbulence in the air flow and the collected material also serves as wear protection.
13 years is a very long time for a lining. Our PUCEST material is extremely low-wear and keeps its promises. The old lining was removed, new segments were cut from PUCEST sheets in 12 mm with aluminum perforated bleaching insert and screwed into the hopper. When dismantling the hopper, the customer cut away the permanently attached belt seal and our fitters quickly produced a new removable construction on site. This means that all components can be replaced quickly and easily.
Our customer’s concrete discharge hopper with a rubber lining was badly worn. Our installation team dismantled the hopper, removed the rubber lining and took the exact dimensions of the inlay. Now our PUCEST panels can be cut to size and the inlay is completely manufactured on site. Reassemble everything and the funnel is perfectly protected against wear. Reduced cleaning effort, much longer service life and therefore cost savings. PUCEST the original, made in Germany.
The inlay of the funnel is badly worn. Our team dismantles the hopper, removes the old lining, then cleans and primes it. Now the new PUCEST lining made of 12 mm sheets with perforated aluminum plate in 85 Sh can be installed. Before the new hopper can be attached, a new mixer cap is fitted and the hydraulic lines are replaced. Everything is ready for use again…
Our customer’s concrete mixer is leaking, with liquid and material constantly escaping from the mixer lid. We welded 2 mm thick metal sheets into the gap and then sealed everything with PUCEST TIX filler. The mixer is now absolutely leak-proof.
The transfer point was perforated several times and falling material had to be removed daily. In addition, the material guide on the sides had already been “patched” several times. Our installation team first installed a PUCEST head scraper so that material residues underneath the conveyor belt were no longer a problem. Now we were able to line the sides at the transfer point with the PUCEST material guide. In addition, impact protection was installed at particularly affected areas.
The old lining consisted of wear plates and rubber flaps and was completely worn out. A permanent solution had to be found. First of all, the old lining had to be completely removed.
We found a defective rotor and worn mixing arms. Normally, the mixer would be disposed of and a new one would have to be purchased. However, our experts were able to perform a true miracle and bring the mixer back to life. With the PUCEST universal mixing arm and the many years of experience of our fitters, we were able to do it again this time…
Replacement of a silo ventilation filter. The old filter was extremely clogged and no longer fulfilled its function. A repair was not possible.
Lining of an elevator bucket with PUCEST sheets 10 mm in 85 Shore and the PUCEST “round corner”. Even before the bucket is installed in the factory, we take over the lining to prevent adhesion right from the start.
Our customer’s mixer lining is completely worn out. In addition, the discharge hopper has considerable cracks. A second mobile hopper is also to be lined with PUCEST. We bring the external hopper to our workshop so that we can work on the project in parallel.
A sedimentation tank is used to collect suspended solids from the water at the bottom of the tank. To prevent the concrete residue from hardening, an agitator is used to keep the recycling water and suspended matter in motion.
The discharge hopper of our customer’s concrete mixer is completely worn out. Material sticks everywhere and prevents the concrete from running off smoothly. The discharge hose for filling the vehicles is also completely worn out.
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.
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.
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 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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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!
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.
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
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.
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.
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).
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.
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.
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.
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.
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 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…
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.
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.
