Remanufacturing is the process of disassembling a machine into its individual components and then rebuilding it to meet current standards. This process is more comprehensive than a rebuild. A grinder rebuild typically involves inspecting, cleaning, and replacing worn or broken parts of the machine with a new one. Parts that are still functioning will not be replaced as long as they meet the manufacturer’s acceptable wear limits.
Remanufacturing a grinding machine involves a thorough assessment of all the components of the machine, and each of these components is restored to manufacturer standards. The result will be a machine that meets or even exceeds OEM specifications.
So, what exactly are remanufactured grinders? By definition, they are grinders that have been rebuilt with modern mechanical, hydraulic and electrical capabilities making them better than new equipment. Remanufactured grinders typically cost between 30% to 70% less than brand-new grinder machines.
The Process of Grinder Remanufacturing
At GCH Machinery, our grinder remanufacturing service involves four main processes.
1. Tear Down & Evaluation
The remanufacturing process begins by disassembling the grinding machine. The purpose of this stage is to evaluate or assess the machine’s condition. The machine is stripped completely to the bare casting. All component parts are also removed and disassembled. During this phase, the main machine casting will be cleaned and checked for any structural damage. All major cast components are hand sanded, filled and primed then sent to our paint shop. Machines are painted to customer specifications and the guards to OSHA Safety Yellow.Â
2. Cleaning & Inspections
Here, all the grinding machine components will be cleaned thoroughly. This makes it easier to identify any deficiencies, flaws or signs of damage. Defective parts are either replaced with new ones or newly remanufactured to meet the original manufacturer’s specifications. We never compromise on the quality of work performed. Our focus is on delivering excellence, ensuring that the remanufactured grinding machine meets or surpasses the original standards set by the manufacturer, and we have been doing that for years.
3. Scraping & Alignment
Many grinding machine components will be scraped and flaked by experienced technicians. Upper, middle and lower slides will be precision ground and hand scraped and flaked as well as truing components to their castings. Scraping involves refining the surface to ensure that they are properly aligned. This will further enhance the remanufactured machine’s performance.
4. Inspection & Testing
The remanufacturing process is not complete without a thorough inspection and testing. All functional aspects of the machine, such as alignments, lubrication, electrical controls, hydraulics or pneumatics are verified to ensure they operate smoothly. This is where we make any necessary adjustments to the machine. All remanufactured machines receive our standard quality acceptance. With that the equipment is to be functionally runoff on ONE (1) part in our facility before shipment. The customer is welcome to be present. A full CPK runoff can be requested by the customer and quoted with the machine at the time of purchase.
The Advantages of Remanufactured Grinders
There are many advantages of remanufacturing grinders compared to buying brand-new. These advantages include:
- Cost savings compared to new machines: Remanufactured grinders are typically less expensive than brand-new machines, offering significant cost savings for businesses on a budget.
- Reduced environmental impact: By opting for a remanufactured grinder, you’re diverting a machine from the landfill and reducing your company’s environmental impact. This is because remanufacturing reuses the existing components of the machine base, rather than producing new.
- Improved performance and reliability: Remanufactured grinders undergo a rigorous refurbishment process that includes replacing worn-out parts and upgrading components to improve performance and reliability. As a result, remanufactured grinders perform just as well as new machines.
- Compliance with industry standards and regulations: GCH remanufactured grinders are brought up to current industry standards and regulations, ensuring compliance with safety and environmental requirements.
- Availability of customized options: Remanufactured grinders can be customized to meet specific business needs, such as specialized tooling, controls or automation options, etc.
What’s Included in a Grinder Remanufacturing?
- All ways, slides and moving surfaces are precision hand scraped and flaked
- Completely re-tooled set-up and SPC and CPK run-off on your part
- New precision-scraped Filmatic bearings that are matched to the new spindle surfaces
- All spindles are ceramic coated or chrome plated and ground.
- Choice of color-customer selection
- New grinder tooling
- All bearings, roller, ball and angular contact are replaced with new matching precision sets
- New hydraulic valves
- New steel pipes, hydraulic hoses and fittings
- New hydraulic pumps, filters and motors.
- New electrical, motor starter and fuse blocks
- New SLC, PLC and CNC controls
- New control console color CRT and push buttons (option)
- Complete AutoCAD schematics (electrical, hydraulic, pneumatic)
- Special load monitoring devices
- New auto lubrication controls, new lube blocks, steel lines and fitting
- New motion control devices, servos and steppers
- New NEMA 12 electrical enclosures
- New automation for loaders and unloaders
- New gages for in-process and post-process
- New auto wheel balancers
- New precision ground ball screws and nuts
- New panel disconnects, wiring and transformers
- Global warranty standard
- New constant surface footage
- Complete turnkey package
Factors to Consider when Choosing a Remanufacturer
Before choosing a remanufacturer for your grinder, consider the following factors:
- Expertise and experience: Look for a remanufacturer with expertise and experience in refurbishing grinders to ensure quality work and reliable performance
- Quality of materials and parts used: Check the remanufacturer’s sources of materials and parts to ensure they use high-quality, durable components.
- Inspection and testing processes: Ask about the remanufacturer’s inspection and testing processes to ensure that the remanufactured grinder meets industry standards and performs as expected.
- Warranty and support: Look for a remanufacturer who offers a warranty and ongoing support to ensure that your refurbished grinder continues to operate reliably and efficiently over time.
Choose GCH Machinery to Remanufacture Your Grinder
Remanufacturing your grinder has many benefits, from improved performance to reduced environmental impact, all at a lower price. GCH Machinery is the leading grinder remanufacturing service provider. We also offer rebuilding, repair and retrofitting services.
Call us today to book your machine for our remanufacturing service or learn more about our services.