{"id":9350,"date":"2021-01-11T20:28:09","date_gmt":"2021-01-11T20:28:09","guid":{"rendered":"https:\/\/polydeck.wpenginepowered.com\/?p=416"},"modified":"2021-01-11T20:28:09","modified_gmt":"2021-01-11T20:28:09","slug":"reducing-costs-and-maximizing-efficiency-are-winning-strategies-for-profitability","status":"publish","type":"post","link":"https:\/\/polydeck.com\/es\/reducing-costs-and-maximizing-efficiency-are-winning-strategies-for-profitability\/","title":{"rendered":"Reducir costes y maximizar la eficiencia son estrategias ganadoras para la rentabilidad."},"content":{"rendered":"\n

The future (and fate) of the energy and industrial industry hinges on constant innovation and the adoption of smarter, more efficient ways of doing business. Industry Expert, Ron Bennett, talks about the most effective measures needed to adapt to coming changes.<\/strong><\/p>\n\n\n\n

Ron Bennett has spent most of his life around coal. After working in the magnetite industry for 25 years he joined Polydeck 17 years ago in a sales position. Today, he is a Senior Industry Expert with the company, where he puts his depth of knowledge and years of experience to use as the lead application advisor for their entire energy and industrial division.<\/p>\n\n\n\n

In addition to overseeing fleet and safety responsibilities, Ron works closely with Polydeck\u2019s customers in the energy and industrial industry to help develop groundbreaking solutions to their production challenges. His advice is critical in helping both Polydeck and its customers decide on the most effective courses of action to take in response to new trends and shifts in the industry.<\/p>\n\n\n\n

Lately, he\u2019s been keeping his eye on the plummeting price of coal and thinking about what it might mean for the future of energy production in the US\u2014particularly the costs of doing business for coal processors.<\/p>\n\n\n\n

\u201cDemand is at a near all-time low,\u201d Ron notes grimly, \u201cThe price has bounced back a bit from the record warm winter we saw last year, but there\u2019s still lots of stockpile on the ground and parts of the country saw a mild winter again this year. The price is currently around $40 a ton for steam coal and $85 a ton for metallurgical coal\u2014and that\u2019s not good. We\u2019ve already had two major coal companies go bankrupt as a result, so the domestic industry today faces a huge challenge.\u201d<\/p>\n\n\n\n

Despite the downward trends, Ron sees opportunity for processing plants to shift their cost burden in a positive direction by making operational changes that reduce their processing costs. These costs include a variety of production factors, such as planned or unplanned downtime, screen efficiency, proper sizing, magnetite recovery, and maintenance. Every point of improvement has some effect on an operator\u2019s overall costs; collectively, however, they can have a tremendous impact on the bottom-line.<\/p>\n\n\n\n

The energy and industrial team at Polydeck has over 150 years of industry experience and they understand the difficulties operators face in bringing production costs under control. As Ron puts it, \u201cIf someone has a coal issue, you can be sure we\u2019ve dealt with it before.\u201d<\/p>\n\n\n\n

Polydeck relies on the team\u2019s combined knowledge and their strong relationships with its customers to help the company design and manufacture innovative products that drive those costs down.<\/p>\n\n\n\n

Reducing Costs on the Scalping Screen<\/strong><\/p>\n\n\n\n

Raw coal scalping can be a problem when there is a high presence of clay in the run, which makes the coal \u201csticky.\u201d As the coal passes through the screen deck, the clay adheres to the screen and clogs up the apertures, slowing the production flow and creating inefficiency. Eventually, the run has to be paused while a crew clears the screen deck of clay\u2014a costly work stoppage by any measure.<\/p>\n\n\n\n

\u201cI\u2019ve seen an operator have to shut down three times in a single shift to clean their deck,\u201d Ron recalls, \u201cThat makes the run really expensive to clean, process, and put in a car. These days, that just won\u2019t cut it.\u201d<\/p>\n\n\n\n

To address these types of applications, Polydeck developed specialty rubber products. Because the rubber panels are extremely flexible, they shed the clay and maintain the screen\u2019s efficiency. Not only does the pass-through volume stay consistent, but by not having to shut down the screen to clean off the clay, the operator also saves a lot of downtime and labor costs.<\/p>\n\n\n\n

Polydeck\u2019s polyurethane products for raw coal applications similarly reduce maintenance and downtime costs by providing superior wear life and fast, easy change out. These products are a direct result of Ron and his team working closely with customers to understand what they need their equipment to do.<\/p>\n\n\n\n

Reducing Costs in Drain-and-Rinse Applications<\/strong><\/p>\n\n\n\n

Drain-and-rinse applications wash magnetite off coal and allow operators to recover the material, which is important because magnetite prices are at an all-time high. Just a few years ago, magnetite sold for around $90 per ton. Now, because magnetite is no longer domestically produced, the import and shipping costs\u2014along with a lack of competition\u2014have driven up the price to over $300 per ton.<\/p>\n\n\n\n

This makes magnetite recovery a profitable task, but it also presents a completely different challenge for processors. In this case, particularly, getting the correct size distribution on the screens is critical to ensuring that the maximum amount of magnetite product is recovered.<\/p>\n\n\n\n

To ensure proper sizing and drain rates, Ron advises clients to adopt a solution that incorporates Polydeck VR panels on the top deck with continuous slot panels or profile wire panels on the bottom decks: \u201cThe easy change out can dramatically lower an operator\u2019s maintenance costs and decrease their downtime.\u201d<\/p>\n\n\n\n

Reducing Costs in Recovery Applications<\/strong><\/p>\n\n\n\n

Consistency is key in any business, but it\u2019s of extreme importance in the fine coal circuit, where recovery can come down to a mere .02 mm difference in size. Ensuring consistency gives the operator the confidence that they\u2019re putting 100 percent of their product on the ground and not throwing away valuable product due to inefficiency.<\/p>\n\n\n\n

\u201cProducing consistently sized panels is one of Polydeck\u2019s core competencies, and it\u2019s a strong selling point for our products\u201d Ron explains, \u201cAll of our rubber and urethane panels are manufactured with an injection-molding process that produces a consistent aperture size from panel to panel. We even back it up with a product performance guarantee: If our panels are ever not to the customer\u2019s spec, we\u2019ll replace them at no cost.\u201d<\/p>\n\n\n\n

Reducing Costs in the Supply Chain<\/strong><\/p>\n\n\n\n

An often overlooked area in which an operator can reduce their operational costs is in the ordering and fulfillment phase of supply inventory. An operator who partners with a supplier that has sufficient warehousing and logistics can keep less stock on site and instead rely on rapid delivery of replacement stock to maintain profitable production levels.<\/p>\n\n\n\n

Again, Ron points to Polydeck as a good example of the type of partner an operator can leverage to help reduce their costs: \u201c[Polydeck\u2019s] products are manufactured in Spartanburg, SC and stored in three distribution centers strategically-located in the eastern US coal fields\u2014in Morgantown, WV; Chapmanville, WV; and Ridgeway, IL. Additionally, Polydeck has strategic partners in Eastern and Western Canada who store product for customers so that they are on hand when needed. This means that we can guarantee availability of product and fast delivery to the customer\u2014usually by the next day. It also means the customer can save more money by reducing their stocked product levels.\u201d<\/p>\n\n\n\n

The Future of Cost-Savings<\/strong><\/p>\n\n\n\n

Ron regularly sees the benefits of greater efficiency when dealing with customers. \u201cThe maintenance savings alone with a modular deck is substantial,\u201d he explains, \u201cI was working with a processing operation to help them transition to a new modular Polydeck screen. While I was there, the supervisor and I watched his crew change out their old metal screen. It took four guys with torches and impact tools several hours to do the work.\u201d<\/p>\n\n\n\n

This kind of downtime and labor-intensive maintenance was killing the client, but with a new Polydeck screen, it would only take a single team member a few minutes to swap out a 1×1 panel. After installing the Polydeck screen, the customer saw a dramatic improvement in the entire plant.<\/p>\n\n\n\n

\u201cWhen I went back,\u201d Ron says proudly, \u201cthe supervisor told me to walk the plant and report back what I found. The facility was the cleanest I had ever seen, and the entire production was running smoothly. When I told him so, he said, \u2018That\u2019s exactly what I wanted you to see; my guys have more time to take care of other things instead of constantly replacing screens.\u2019\u201d<\/p>\n\n\n\n

This is the sort of opportunity for change and improvement that Ron sees taking place for operators across the country. \u201cThe industry is going through a sea of change as the world transitions from traditional fossil fuels to other forms of power generation. Just last year, coal dropped below 50% of all forms of power generation for the first time.\u201d<\/p>\n\n\n\n

He remains positive about the future, however. \u201cLook, everyone needs to remember that coal still keeps the lights on. Despite all the changes around us, coal isn\u2019t going anywhere for the time being.\u201d<\/p>\n\n\n\n

Coal processors know that they have to make changes to adapt to the new realities in order to remain profitable. The easiest way to do that is to examine their operation from top-to-bottom, find those areas where improvements can be made, and then partner with vendors who can help them implement those improvements.<\/p>\n\n\n\n

Without the capacity to overcome production bottlenecks and inefficiencies, increase the productivity value of their work force, and maximize the quality and consistency of the product throughput, processing operations could be forced to shutter if the cost of coal continues to drop.<\/p>\n\n\n\n

The good news for operators is that they aren\u2019t alone. Companies like Polydeck, and experts like Ron Bennet and his team, work hard to come up with solutions to the production challenges facing coal processors. They know that the future (and fate) of the industry hinges on constant innovation and the adoption of smarter, more efficient ways of doing business.<\/p>\n","protected":false},"excerpt":{"rendered":"

The future (and fate) of the energy and industrial industry hinges on constant innovation and the adoption of smarter, more efficient ways of doing business. 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