Your challenges

We reduce machine downtimes as well as servicing costs through practical component design and by providing technical advice during the production process. We are also your contact for additional challenges.

Finding challenges

With modern production plants, we assist our customers with everything from application advice through to series production.

The challenges involved in the production processes of various industries are extremely diverse. Our technicians and engineers are specialised in identifying the nuances of every challenge and incorporating them into the solutions offered.

Filer challenges:

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Process reliability
Extended service life
Process optimization
Cost/time savings
Challenges

Process reliability

Abrasion resistance

In sectors such as the pharmaceutical or food industries, the cleanliness of components in the manufacturing process is vitally important. Fouling or metallic abrasion can lead to contamination of the end product.

Extended service life

Adhesion / Weld deposits

When metallic materials are welded together, glowing matter known as weld spatter frequently flies around during the welding process. If this matter then lands and cools on equipment components or the production parts themselves, it generally adheres to them.

Process optimization, Cost/time savings

Heating process

To enable thermal processes to function, the tools or the entire system are heated to the required temperature. A process that ends after each period of heating is referred to as a dynamic process. A static process is one in which heating occurs at the start of a long production process and is readjusted by sensors if necessary.

Extended service life

Chemical resistance

The ability of materials to resist the effects of chemicals is called chemical resistance. Corrosion resistance, resistance to aggressive media, resistance to pressure and wear are the primary challenges.

Process optimization

Electrical insulation in combination with mechanical requirements

When thermally and electrically insulating parts are used in the different procedures, choosing the right high-temperature material is key.

Cost/time savings

Energy loss

During thermal processes, contact between hot surfaces transfers heat into the machine. Likewise, hot tools radiate the temperature.

Process reliability

Exact process management

The inherent functions of components and assemblies made from DOTHERM or ISOCOS and DOCERAM materials make industrial processes possible in the first place because they protect those involved in the process from exposure to excessive temperatures, electrical voltages and active media.

Process optimization

Induction: metal-free handling and positioning

In industrial manufacturing processes, conventional furnace processes are increasingly being replaced by inductive heating. This is a process whereby electrically conductive materials are heated with the help of eddy-current losses generated within the material.

Process optimization, Cost/time savings

Reducing servicing costs

In addition to the manufacturing process of a company, servicing has a major influence on production reliability and therefore on the costs of the end products.

Extended service life

Corrosiveness

Corrosion describes a reaction of a material with its environment, which brings about a measurable change in this material and can therefore lead to corrosion damage. The term was originally only applied to metals but is now applied in general to all materials - including polymers, glass and ceramics.

Process optimization, Cost/time savings, Process reliability, Extended service life

Mechanical load: components / tools break

External mechanical loads, sometimes accompanied by high temperature influences, frequently cause conventional materials to fail and ultimately leading to tool breakage. In this case, the mechanical strength of components and tools decreases as the temperature increases.

Process optimization

Freedom from metal

High-performance ceramics, also referred to as industrial or engineering ceramics, are non-metallic materials based on ceramic powder that are produced by a process of sintering and optimised for technical applications.

Process optimization

Personal protection

In the case of thermal and electrical processes, special care must be taken to protecting the people working there. Added to the fact that process heat makes working at these types of machines intolerable, there is the danger of burns or electric shocks if safety measures are not observed.

Process reliability

Process reliability

Wear, deformations and breakages are critical phenomena in the production process. The function of quality-relevant components made from conventional materials can quickly deteriorate in very challenging application areas.

Cost/time savings

Reducing quality assurance costs

Only a few production processes guarantee 100% quality if such a thing is even possible. Fluctuations in the process and gradual process inaccuracies lead to quality problems or to the failure of a component. The more uncertainty factors there are in the process, the higher the workload in quality control when it comes to avoiding rejects.

Extended service life

Abrasive wear

In contrast to ceramics, polymers and metals usually have much lower hardness values and are far more susceptible to wear. Since wear is defined as the progressive loss of material from the surface of a solid body, the dimensional accuracy in friction situations (tribosystems) is directly related to the resistance to wear of the material used.

Extended service life

Thermal wear

As temperature increases, the mechanical strength of materials reduces. Wear increases at an exponential rate. Conventional materials are unable to withstand sudden and high temperature differences (thermal shock). In addition, dimensional stability is then frequently no longer guaranteed.

Process optimization

Avoiding unscheduled machine downtime

The primary cause of machine downtime is the unexpected failure of specific components of a production plant. Machine downtime or machine failure causes high costs firstly due to the urgent need for spare parts and secondly due to “non-productivity”.

Extended service life

Preventing microcracks

As two surfaces in contact slide off one another, there is a possibility that the contacts created will not separate again at their original interface. The surface disruption that occurs describes the formation of microcracks either on or just below the surface due to cyclical loading and unloading (e.g. ball bearings).

Extended service life

Wear in the process

Wear (material removal) on components is an important risk factor during the production process. Due to the external application of loads, standard materials frequently show signs of heavy wear.

Extended service life

Contamination of the end product

In sectors such as the pharmaceutical or food industries, the cleanliness of components in the manufacturing process is vitally important. Fouling or metallic abrasion can lead to contamination of the end product.

Process optimization

Tool failure due to thermal shock

Materials are frequently upgraded to improve or optimise their performance. Steel, for example, is tempered or hardened. Likewise, handling a glowing product, as is the case in the glass industry, is also unavoidable.

Challenges

Other challenges

Is your challenge not listed? Don’t hesitate to contact us. We work closely with our customers to develop bespoke solutions for every industry.

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Our materials

The MOESCHTER Group was founded as a technology company dedicated to manufacturing user-friendly products from high-performance materials. More than two decades later, it has developed a material portfolio that covers a wide range of requirements for diverse industrial application areas.

Our solutions

We demonstrably reduce machine downtimes across a range of production processes through practical component design and by providing technical advice during the process.

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