Revolutionizing Charcoal Processing: How Webster Chain Extends Chain Life and Reduces Maintenance Costs

Downtime is costly in charcoal processing. Shutting down operations to replace a bucket elevator chain leads to substantial lost production time and rising maintenance costs. 

But what if you could extend the life of your equipment and reduce maintenance and downtime at the same time?

The Challenge: Curbing Maintenance Costs and Frequent Chain Replacements

A national charcoal processing company Webster works with had been using a standard bucket elevator chain. While this chain was reliable, it still required replacement every 24 months, leading to financial strain and lost production hours due to downtime. The company wanted to know what they could do to reduce the amount of times a chain needed to be replaced, extending the product’s life span and ultimately improving operational efficiency.

The Solution: Upgraded Stainless Steel Components

After assessing the company’s operational needs and challenges, we recommended upgrading their chain to a TS956 with stainless steel components. Stainless steel helps prevent pin and bushing corrosion, which significantly increases the wear life of the chain.

The upgraded chain is part of our standard service offering, designed with a focus on total cost of ownership for our customers. This engineered design ensures the company will not only see a reduction in maintenance costs but also an overall boost in productivity.

Charcoal Change in Action

As a result of this upgrade, the charcoal processing company saved $57,500 in just one year!

Over the lifespan of the upgraded chain, the company is projected to save a total of $230,000 thanks to the new chain design.

These savings were achieved all without sacrificing performance, allowing the company to focus on its core operations instead of worrying about future equipment failures.

The Webster Advantage: Engineering for Longevity and Performance

Webster engineers chains with the unique needs of its industry partners in mind. Charcoal processing is a challenging environment that requires equipment that can withstand the conditions and deliver optimum performance.

For that reason, we’re committed to using high-quality, USA-made steel, which offers enhanced tensile and fatigue strength, ensuring long-lasting performance. Our process includes perfect pitch hole processing, delivering high-quality, fatigue-resistant components that provide extended service life and reduced maintenance. 

Our in-house, highly controlled heat-treating processes further enhance the chain’s strength and durability, optimizing wear resistance and extending the overall lifespan of the chain.

And when your company requires a custom solution, we’re here to provide engineering services, including application and wear analysis, with design, suggestions, and specifications, all to help your business run smoother and more profitably.

If you’re ready to optimize your company’s operations with solutions that reduce downtime, increase productivity, and deliver immediate cost savings as well as long-term financial benefits, give us a call today or contact us now. We’re here to help you find custom solutions that work for you.

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