Type of loss:
A 600,000 sq. ft. corrugated processing plant was flooded with five feet of river water. The muddy water contained heavy levels of corrosive chemicals and fertilizer from the surrounding farms. All of the equipments controls, processing machines and the 12,000 ft. of powered roller conveyor were saturated and rusting by the time the water receded.
Challenges to overcome:
1. This is one of the larger corrugated plants the customer owned and there was not enough capacity at their other plants to cover orders.
2. The plant utilized a select few OEM’s throughout the plant for their equipment; the OEM’s did not have the human resources or spare parts available to support the customer to repair their processing equipment.
ERS, Inc. mobilized over 60 technicians and immediately started to mitigate further damage by spraying rust inhibitor over all contaminated equipment, draining and removing water from control cabinets and conduits. Over the next five weeks our engineers, electricians and mechanical technicians completed the following tasks:
1. Replaced all electronic components from the water line down in over 600 control cabinets.
2. Cleaned and relabeled all wiring and hardware components in over 600 control cabinets.
3. Disassembled command console for corrugated line.
4. Removed old wood floor and built new wood floor for command console.
5. Reinstalled and re-terminated over 3000 wires to command console.
6. Ultrasonically cleaned over 36,000 conveyor rollers.
7. Removed and replaced over 44,000 bearings in conveyor rollers.
8. Removed rust and contamination from corrugated line and eight boxing/printing lines.
1. Customer was back into production in five weeks.
2. All equipment came back online as required.
3. OEM’s validated all of ERS replacement components and work performed to continue honoring warrantee of customer’s equipment that was in place.