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Kawasaki Rail Cars (KRC) Had A Weighty Problem

Challenge: Kawasaki Rail Cars (KRC) , a New Jersey-based manufacturer, had a weighty problem: Where to find heavy-duty caster wheels that can traverse uneven, cracked floors while handling loads of more than 30 tons? The issue was with a component called a transfer table – a part of the assembly line when a nearly-finished railroad car is picked up and rotated 90 degrees to align with the exit from the manufacturing plant. The three-wheel industrial caster wheels mounted beneath the transfer table were ineffective in handling the weight, often resulting in failures and lost productivity.

RailCarTrans

“We had all kinds of problems with the existing wheels on the transfer table,” said Nehru Satahoo, Assistant Manager of the Production Engineering Department at KRC. “The floor of the building where the transfer table is used is not even, there are cracks and these are caused by the size and weight of the cars, and the load generated by the movement angles that caused the wheels on the transfer table to continuously fail. These failures caused production delays and extra work, amounting to thousands of dollars each year in parts and labor.”
Solution: KRC worked with Caster Concepts to design a new four-wheel heavy-duty caster that eliminated the failures brought on by extreme stresses that were unmanageable by the three-wheel system. The wheels were coated with a special 70d polyurethane that was specifically designed to manage the extremely high weight.
“(Caster Concepts) listened to the issues we were having and understood them in detail, and involved us directly in the process,” Satahoo said. “With our input, Caster Concepts created a product in a timely basis, with quality that was spot on. The product they produced is low maintenance and reliable, so production delays are no longer a concern.”

Help In Quick Fashion – Heavy Duty Conveyor Wheels Exceed Expectations

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Problem: A mushroom processor was struggling to find replacement heavy-duty casters to mount on its conveyor system, which serves a critical function in that it pushes trays of unprocessed vegetables through its production line. Calls to other industrial caster suppliers resulted in timing or cost issues that were unacceptable, given the urgent need for replacement heavy-duty caster wheels.

Solution: Caster Concepts was able to easily match the form and function of the outdated industrial caster wheels, providing a quality custom heavy-duty caster wheel at a reasonable price, and in a very quick timeframe. “Caster Concepts was willing to help. They provided drawings to confirm my requests, answered all my questions and requests, provided good pricing, and built a quality custom caster per specifications,” said Danny Wardle, facilities manager for Fillmore, UT-based Mountainview Mushrooms. “I have since ordered again and received the same quality and customer service for a competitive price.

Special fold up caster by Caster Concepts

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Challenge: Blade Industrial, a Michigan-based supplier of manufactured parts, such as molded rubber and die-cut and extruded parts, to a multitude of customers – including the U.S. Government – had the chance to earn incremental government business by providing supplies in the heavy-duty caster wheel realm – a market with which they were not previously familiar.

Solutions: Caster Concepts provided the know-how, service and price that Blade needed to earn the extra heavy-duty caster wheel business – and to satisfy its best customer. “The product was delivered on time, and as quoted,” said Joe Smotherman of Blade Insustrial. “From a customer standpoint, Caster Concepts provided great service, from the RFQ to the delivery.”

WOW what a nice caster!!

NextGen

Engine transports rely on casters from Caster Concepts

“Zach and the entire team at Caster Concepts provided outstanding service. The team worked with us from the start of the first contact we made, providing fast response and handling the wide range of details that we required in configuring our custom casters. The options provided exceeded our requirements and the price was very competitive. We received our first order and were impressed with the outstanding quality of the product. Our team was full of excitement!

“What the casters did for our product was amazing. We now have one first class caster on our product that is second to none. Our product holds aircraft engines that run in the millions of dollars and the durability of the caster is very important. We look forward to a very long relationship with Caster Concepts due to the extra mile taken to help our company and the top quality of the product.

“Once again, thanks for such an outstanding job.” Doug Winter, NextGen Aero Support

Extreme Casters Move 35,000 lbs. Load

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Problem:

The USAF needed to replace worn out 12″ wheels, with tapered bearings, on window change stands for their B-1B aircraft.

Solution:

 Says the Technical Sergeant in charge of acquisition, “Caster Concepts was more than willing to make the wheels the way we needed to fit our application. The overall process went smooth without any problems. I am extremely satisfied with the service and the quick turnaround of the product.”

The Sergeant went on, “I would say I am 100% satisfied with Caster Concepts’ product and turnaround time. We have had the wheels on our stands for a little over a month now. They are 10 times easier to move around the aircraft and increased the capabilities with the new wheels.”

Interested in finding a motion solution to fit your needs? Please contact Jewell Flora  jflora@casterconcepts.com or 1-517-680-7918 for an evaluation and more details for your custom application.

US Air Force praises Caster Concepts product and turnaround time

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Problem: The USAF needed to replace worn out 12″ wheels, with tapered bearings, on window change stands for their B-1B aircraft.

Solution: Says the Technical Sergeant in charge of acquisition, “Caster Concepts was more than willing to make the wheels the way we needed to fit our application. The overall process went smooth without any problems. I am extremely satisfied with the service and the quick turnaround of the product.”

The Sergeant went on, “I would say I am 100% satisfied with Caster Concepts’ product and turnaround time. We have had the wheels on our stands for a little over a month now. They are 10 times easier to move around the aircraft and increased the capabilities with the new wheels.”

Interested in finding a motion solution to fit your needs? Please contact Jewell Flora  jflora@casterconcepts.com or 1-517-680-7918 for an evaluation and more details for your custom application.

Forward Progress: TWERGO ® Provide Caster Efficiency to Automaker

Twergos

Problem: Wheels were difficult to push around shop floor.

Solution: TWERGO ® wheels provided easy-to-move ergonomic roll-ability

Caster Concepts’ TWERGO ® wheels are part of increased mobility and caster efficiency at a major automotive supplier.

A engineering manager recently purchased some heavy duty TWERGO ® for moving transport carts for front suspension modules. The carts move by an electric tugger and manually. Each cart weighs approx. 2500 lbs.

Explains the manager, “Initially I contacted Caster Concepts to determine if their TWERGO ® casters would be suitable for my application. Upon confirmation, they provided me with a solution based on the parameters I had given them. They were very helpful in getting a set of casters shipped out quickly for me to trial. Once the casters proved to be robust, they were quick to ship out a large order so I could retro-fit all the carts in our plant.”

“Caster Concepts service is very professional and friendly. All my questions were answered very quickly and comprehensively,” continues engineering manager.

“The product is excellent! TWERGO ® caster reduced the manual efforts to move our carts by as much as 50%. Even after six months of steady use, the efforts to move the carts remain much lower than the previous caster. All our employees who use these carts will agree that this is an excellent product.”

Interested in finding out if TWERGO ® are a fit for your workplace? Please contact Jewell Flora  jflora@casterconcepts.com or 1-517-680-7918 for an evaluation and more details for your custom application.

FAQ’s

Twergo®’s Impress

“Everyone was thoroughly impressed with the performance of the Twergo Wheel”  Project Engineer

Caster Performance

“I will use these casters on all future designs and not hesitate to recommend them to other designers” Tool design engineer

Smooth Rolling Casters

“Everyone comments on how effortless and smooth the casters rolled, a substantially noticeable difference from a conventional style wheel in the same application” Precision assembly operation

Smooth Rolling Casters

“Everyone comments on how effortless and smooth the casters rolled, a substantially noticeable difference from a conventional style wheel in the same application” Precision assembly operation

Twergo’s Meet Challenge…

Everyone comments on how effortless and smooth the casters rolled, a substantially noticeable difference from a conventional style wheel in the same application Precision assembly operation

“Thanks for providing such a quality product in a day and age where often times we are disappointed in the products delivered by our suppliers.”  Aerospace tool builder

Flawless Wheels

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Engineering by Caster Concepts

The wheels performed flawlessly and everyone is surprised at the complete lack of any vibration. Kudos to all involved for a job well done!

-Industrial Design Engineer, Farmington, MI

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