Laser Welder Yields Fast, Precise Mold Repair

Located in New Orleans, Louisiana, Intralox stands as a testament to innovation in the conveyor belt industry. This billion-dollar powerhouse serves 60,000 customers spread across more than 100 countries. With a workforce exceeding 3,300 employees, Intralox has firmly established itself as a global leader in modular plastic belting.

Intralox's success story began with its invention of modular plastic belting. Today, the company offers over 40 belt series and hundreds of series-and-style combinations. Its product line caters to various industries, from food processing manufacturers like Nestle and Mars to logistics companies such as Amazon and FedEx.

To better serve its customers, Intralox has organized its operations into three distinct business units: food, industrial and logistics and material handling. Each unit has its own team of dedicated engineers, account managers and technical support staff. This industry-specific focus enables Intralox to develop tailored solutions that address the unique challenges faced by its clients.

Intralox also employs a direct sales model, giving them an intimate understanding of their customers' problems. Their network of global assembly centers enables them to support customers critical conveyance needs. This close relationship with customers and their strategically located R&D centers across the U.S. enables Intralox to stay at the forefront of innovation in the conveyor belt industry.

Precision Repairs Under Pressure

Despite its impressive capabilities and global reach, Intralox faced a significant challenge in its toolroom operations. The company's diverse product line means that its molds come in all shapes and sizes, often with intricate designs and hard-to-reach areas. When these molds need repair, the stakes are high. Having the right mold repair equipment is critical, including the presses to run the molds once they are repaired.

The headquarters facility in New Orleans has 136 molding machines and its Hammond, Louisiana facility houses 99 molding machines for a total of 235 presses, ranging from 250 to 650 tons. “50% of the molds we work on run in the New Orleans facility with another 45% running in the Hammond plant about 50 miles away, and 5% to outside vendors that run our molds,” Chris Howard, Intralox Mold Shop Supervisor, says.

“Emergency repairs are our top priority,” Howard explains. These issues could impact customer orders or even pose safety risks. We need to address repairs immediately, making our repair process, equipment and molding capabilities essential."

However, the main challenge isn’t just about speed. Precision is equally crucial. Many repairs involve extremely small, precise welds on complicated finished surfaces. The toolroom team often finds itself grappling with repairs in hard-to-reach places, pushing the limits of their equipment and skills.

Adding to the complexity, the toolroom frequently has to juggle multiple high-priority requests simultaneously. With only three dedicated moldmakers in their unscheduled repair cell, efficient workflow management is critical.

The integration of the Alpha Laser ALFlak into Intralox's toolroom operations has not only solved their immediate challenges but also positioned them for future growth and innovation.

Their process involves sending a damaged mold to the "DIN CELL" (Do It Now) for evaluation. Meanwhile, the mold technician completes a repair request form with all necessary information to help prioritize each job. This form includes details about the part the mold produces, a brief description of the problem, photographs of the damage, and a sample part highlighting the affected area.

Upon the mold's arrival, the team inspects it and estimates the repair duration based on the damage. If the mold is not repairable, they submit a mold design request for engineering support. Engineering then assigns a designer who orders the necessary materials, including steel, prints and step files, along with all other items required to fabricate a new replacement part. Either Intralox manufactures this part or an outside vendor is contracted for the job.

To complement their refined repair process, they now sought a technology solution to help them tackle these challenging repairs quickly and accurately.

Laser Welding to the Rescue

Intralox found their answer in the Alpha Laser ALFlak laser welding system. This advanced piece of equipment proved to be the game-changer they were looking for.

The Alpha Laser ALFlak is a high-precision laser welding system designed for versatility and accuracy. Its standout feature is a flexible laser arm that can project a great distance, enabling it to reach welding positions even in deep or complex molds effortlessly.

"The ALFlak's flexibility is truly remarkable," says Michael Barsanti, Alpha Laser Sales Manager USA and Canada. "Its turn-tilt optic can pitch from 0 to 40 degrees and swivel a full 360 degrees. This means operators can pinpoint the exact spot to weld, even in the most challenging geometries."

It also features a precision joystick and a microscope setup that enables incredibly fine control. “With the micro settings, we can perform welds using wire as thin as 0.003 inches,” Barsanti explains. “This level of precision is crucial for repairing intricate mold surfaces without distortion.”

The system’s power can also be adjusted on the fly, thanks to a foot pedal that enables operators to change laser parameters without taking their eyes off the microscope. This feature significantly enhances efficiency and accuracy during the welding process.

Intralox integrated the Alpha Laser ALFlak into their unscheduled repair cell, which they had set up seven years prior. This cell is equipped to handle almost any type of repair from start to finish, minimizing downtime and maximizing efficiency.

To make the most of this new technology, Intralox implemented a cross-training program for all three of their moldmakers. “We made it a priority for everyone to learn how to properly set up and run every piece of equipment in the toolroom, including the ALFlak,” Howard says. “This versatility enables us to respond quickly to any repair need that comes our way.”

Precision, Speed and Confidence

The implementation of the Alpha Laser ALFlak, combined with Intralox's strategic approach to toolroom management has yielded impressive results.

Improved repair prioritization: With the ALFlak's speed and precision, Intralox can now address emergency repairs almost immediately. Intralox has significantly reduced its response time for critical repairs, which as minimized safety risks and virtually eliminated any impact on customer orders due to mold issues.

Enhanced flexibility: The unscheduled repair cell, equipped with the ALFlak and staffed by cross-trained moldmakers, can now handle multiple high-priority repairs simultaneously. “We're no longer bottlenecked by equipment limitations,” Howard says. “Our team can tackle whatever comes their way, no matter how complex.”

Increased precision: The Alpha Laser ALFlak has dramatically improved the accuracy of Intralox's mold repairs. They can now perform incredibly precise welds, even in areas that were previously almost impossible to reach. “The quality of our repairs has never been higher,” Howard says.

Faster turnaround: The combination of the ALFlak's capabilities and the team's enhanced skills has significantly reduced repair times. “What used to take days can now take hours and sometimes minutes to complete the repair,” Howard says. And in some cases, they are avoiding days or even weeks of work by eliminating the need for electrode fabrication and EDM sinker work.

“The ALFlak has become an indispensable part of our operations. It's enabled us to take on repairs we couldn't have imagined tackling before, and it's given us the confidence to promise our customers the highest level of quality and service,” Howard says.

Improved confidence: The predictability and reliability of the Alpha Laser ALFlak have boosted the team's confidence in their repair work. “It's a game-changer,” Howard says. “We feel completely confident about the machine's performance, which translates into consistently high-quality repairs.”

Extended mold life: The precision of the ALFlak enables for more targeted repairs, minimizing collateral damage to the mold. They are seeing improvements in mold durability after repairs and can now concentrate on laser welding the right amount without overdoing it or overheating the affected areas.

Cost savings: While Intralox hasn't quantified the exact cost savings, the reduction in repair times and the extended life of their molds have undoubtedly had a positive impact on their bottom line.

Positioned for Growth

The improved efficiency and capabilities of their toolroom have supported Intralox's continued growth. They've been able to maintain their high standards of quality and customer service even as they've expanded to serve more clients across more industries. The integration of the Alpha Laser ALFlak into Intralox's toolroom operations has not only solved their immediate challenges but also positioned them for future growth and innovation.

“The ALFlak has become an indispensable part of our operations. It's enabled us to take on repairs we couldn't have imagined tackling before, and it's given us the confidence to promise our customers the highest level of quality and service,” Howard says.

As Intralox continues to evolve and grow with their customers' needs, the capabilities provided by the Alpha Laser ALFlak will undoubtedly play a crucial role in maintaining their position as a leader in the modular plastic belting industry.