Swagelok looks to educate tire makers on improved hose protocol

SOLON, Ohio—Combating common fluid system leaks in tire facilities is a complicated process, but one of the first steps is to create a mindset change, according to one developer of fluid system products and components used in tire manufacturing operations.

With all the chaos that is common to a tire manufacturing plant, it may seem that these tire leaks are just "part of the job," said Jason Duncan, key account manager for Swagelok Alabama, part of Solon-based Swagelok Co. That's understandable given the high demands and many responsibilities placed on everyone from the plant manager to the junior operator. It can result in a "reactive" mindset where only issues deemed critical are addressed.

The reality is that leaks of compressed air, steam and condensate, and hydraulic oil can cause just one facility well over $4 million a year in losses based on internal surveys and other data provided by Swagelok, perhaps best known as a source for tube fittings, valves and similar components. And this doesn't account for additional losses in efficiencies, production time, repair work and more.

"What we're trying to get our customers to realize is that they can make improvements that will have (a significant positive) impact on their bottom line," Duncan said. "(Tire manufacturers) are aware of the fact they may be experiencing leaks, but it's a hot, intense environment. They may not realize all the steps you can take (to identify and fix these leaks)."

Leaky process pipes are common for tire manufacturers, although it can be difficult to identify exactly how much this waste is costing them. For many companies, this is the biggest culprit for leaks. Every hiss of air or drop of hydraulic fluid from an unsealed valve or fluid system connection represents lost energy and increased costs. Yet there are other benefits in addressing these issues as well that include increased safety for employees, greater operational efficiencies and higher product quality, Duncan said.

Discovering the extent of this issue is the first step to solving it, rather than simply putting a bandage on the problem of air leaks, Duncan said. These process lines are fixable, but also may be optimized in a way that supports those benefits. Swagelok and other companies, for example, offer customers a third-party advisory service where professionals can come to a plant and identify one or more issues, using such tools as hose reviews, a fluid system evaluation with the help of an ultrasonic gun, and others.

Similar to an HVAC system check-up, such services can be scheduled every one to two years, and can identify problems before they become an even larger financial nightmare.

Duncan said there are several applications where tire plants typically can identify costly leaks. One is steam and condensate lines where a single, small leak could cost nearly $4,000 per leak every year, according to data from Inveno Engineering L.L.C. In fact any fluid system connection in a plant can be a leak point, with threaded connections being much more prone to leaks than ones using compression fittings.

Furthermore, with a typical plant having as many as 200 curing presses and each press averaging four leaks, the total annual cost for leaking steam and condensate could be more than $3 million. The realized cost is likely much higher because compromised temperatures and pressure inconsistencies caused by leaks could adversely impact product quality. Curing can account for anywhere between 60 to 90 percent of a factory's total steam consumption.

The wasted energy from a steam and condensate leak can cause safety issues as well since tube replacements will be required more frequently. Steam pipes with tubing and tube fittings and hoses, which are a more reliable and steady solution than threaded pipes, can help.

Hydraulic oil leaks also are common in curing presses and can account for up to $2,500 per year in losses per curing machine, according to Machinery Lubrication. In a tire plant with 200 machines, the cumulative cost is more than $500,000 annually. Costs associated with such leaks include replacement hydraulic fluid, cleanup, disposal and contaminant activities, and potential safety issues.

At $468 annually per leak, leaks from compressed air systems can cause more than $500,000 in losses per year based on an early 2019 Swagelok internal survey that found 180 such leaks when surveying less than 20 percent of a tire manufacturing facility. Mixing room systems often will use threaded pipe systems to manage the proper amount of heat and pressure required. However, these systems also are prone to leaking and can be better served by using tubing with compression tube fittings or hoses as end connections.

"What we want to do is help minimize and dramatically reduce losses for these manufacturers," Duncan said.

There are a couple of best practices that Duncan indicated can help tire manufacturers reduce the likelihood of leaks becoming a financial burden. One is to ensure that there is a documented listing of hoses for each application. It is common practice within the tire manufacturing sector to replace a malfunctioning hose with a hose of a different length or style. This is a problem because an unnecessarily long hose could cause a safety issue and therefore result in other problems for the company. Proper documentation and having a procurement system where the appropriate backup hoses are onsite is critical to avoiding such issues.

Regular safety training sessions also are recommended. Identifying specific classes, and how often they are required, will vary based on the size of the company and the type of products being made. Yet having regular safety training can further reduce the number or length of shutdowns.

Finally, tire manufacturers should understand the impact of increased lifecycle costs. If a hose fails on a press, tires that were produced on that press may need to be scrapped. Plus it could take another three to four days to get that press working because of the need to have the press cool down, powered back up and operating at the proper temperature. Poor training may cause other human errors to further delay this process.

"It's like with a tire itself, if it's rated to (optimally last through) 60,000 miles," Duncan said. "If a consumer has a lead foot, doesn't keep the tires properly inflated or fails to rotate them, you'll probably get less mileage from them."

A higher-performance product, like an insulated hose for steam transport, can not only eliminate a leak, but contribute to more consistent curing temperatures and minimize the potential for worker injury.