Above: Food Process Systems purchased a Mach 500 4020 waterjet from Flow with a Dynamic Waterjet XD cutting head that can cut bevels and compound angles accurately
July, 2024- We will always need a waterjet in our facility for what we do,” says Brian Gilbertson, operations manager for Food Process Systems Inc. in Lodi, Wisconsin. The company designs and custom builds food processing equipment. Its specialty is equipment for vibratory conveyance and vibratory breading batter applications.
The equipment is unique, according to Gilbertson, because the process of moving product does not use any wire belts. “That’s really revolutionized the time and labor savings for customers in the poultry industry especially.” He adds that the equipment improves throughput and reduces defects that can occur when workers touch the product too much before it enters a fryer or freezer.
Founded by President Jim Karpinsky in 1989, FPS has extensive experience with waterjet cutting but not all of its encounters with the abrasive cutting equipment were positive, Gilbertson notes. For example, one machine builder’s customer support was substandard and acquiring parts was problematic.
Nearly a decade ago, FPS purchased a Mach 3 4020 model abrasive waterjet from Flow International Corp. in Kent, Washington. “We just started running everything on that,” Gilbertson recalls.
The Flow Mach 500 waterjet features ultrahigh-pressure pump technology to provide a maximum operating pressure of 87,000 psi and a maximum generated pressure of 94,000 psi.
Based on how well the Flow waterjet performed, FPS bought a Mach 500 4020 from Flow two years ago. The 5-axis machine has a Dynamic Waterjet XD cutting head that can cut bevels and compound angles accurately and a 50-hp HyperJet intensifier pump that provides a maximum operating pressure of 87,000 psi and a maximum generated pressure of 94,000 psi, according to Flow. With that second unit, “we try to run full out as much as possible,” Gilbertson notes.
AVAILABLE WHEN NEEDED
Beveling plates that will be welded together is only needed for about 5 percent of the shop’s waterjet cuts, he estimates, but provides a significant benefit. “Five percent is still crucial for us because the labor savings are just astronomical.” The alternative is to have someone grind bevels into parts. “We don’t have to do that anymore.”
In addition, FPS etches parts on the waterjets, such as circles, to enable fabricators to accurately position components and avoid the painstaking work of laying it out manually, Gilbertson explains. Previously, the company etched with water only, which is a loud operation. Now, after etching is completed and the machine is shut down, a vacuum system removes the spent abrasive garnet from the focus tube. “Running abrasive speeds up that process and turns down the decibels.”
FPS primarily cuts stainless steel from 14 gauge to 1-in. but has waterjet cut stainless up to 2-in. thick, as well as custom projects for certain customers, using copper and aluminum, Gilbertson says. The Mach 3 is frequently used for heavy cutting, such as 1-in. thick material. “That way we can use that [Mach] 500 to do everything else we need at a quicker feed rate.”
Food Process Systems efficiently nests parts to maximize the number of parts extracted per sheet.
Tolerances when waterjet cutting are fairly tight, especially when producing tabs and slots, he says. “We don’t want what’s called a ‘press fit,’ but we don’t want a lot of slop. It’ll vary depending on what we’re doing.”
To keep the machine tank relatively clean, Gilbertson explains that FPS worked with Flow to design a “percolating system” with piping that has perforated holes to control how much air enters and keeps garnet suspended in the water, preventing the sediment from dropping out and building up excessively on the tank bottom. “Once a year at a minimum, we’ll do a full clean-out of the holding tank. That’s a little time consuming, but you get two guys in there for a day, and it’s done.”
Because water is a critical component of the waterjet cutting tool, the water cannot be too hard, he says. As a result, FPS has an oversized softener system to ensure no water hardness problems occur with the two waterjets.
After purchasing the second Flow waterjet, he says FPS did not have time to send someone to receive training, so a team of workers was trained virtually, facilitated by Scott Cole, RSR/application specialist at Flow. “That was great. It’s been a really good experience, very positive for us,” Gilbertson says.
A selection of parts Food Process Systems produced on its Flow abrasive waterjet machines
ONE FOR BOTH
FPS has 20 employees, with 15 of them on the shop floor, and runs one shift , Gilbertson says. One operator primarily runs both machines. “When he gets one loaded and starts cutting, he’s loading the other one. He’ll come back and forth and then performs deburring at the same time.” Another worker is also trained to operate the waterjets when needed to handle excess work or when the primary operator is off work.
The 94,000-psi HyperJet intensifier pump enables easy maintenance and diagnostics, according to Flow.
He adds that a newer operator is running the equipment after the previous one retired and can effectively run both machines. “It’s sad to see that talent leave but it’s the name of the game, so to speak. The new young blood is coming in, and we’ve been pretty fortunate of getting them in and doing what we needed them to do.”
To minimize downtime on the waterjets and other equipment, Gilbertson says FPS “prides ourselves on taking care of our stuff. It’s like anything, you take good care of it, it’s going to take good care of you.”
Although FPS needs waterjet cutting capability in house, which is beneficial for managing a variety of workpiece thicknesses and materials, he says the company plans to eventually purchase a laser cutting machine to complement the two waterjets. However, a laser would be targeted for cutting thin material quickly because a high level of power is required to cut through heavy material and a laser does not impart as fine a surface finish as a waterjet.
After a part, such as one that’s 1 in. thick, is cut in a waterjet, a slight amount of deburring is needed on the edges and “it’s good to go. When I say heavy, I’m saying 1-in. or heavier. That will always be done in a waterjet.” When the Mach 3 starts having issues pop up on a continuous basis, Gilbertson says it will be time to retire it because the shop’s main concern is avoiding downtime. When it is time to replace, Food Process Systems will turn to Flow.
“From our experience,” Gilbertson says, “we just felt that Flow has a superior product plus better support. For lack of a better word, it’s like you’re getting a Cadillac. We don’t need downtime. We need proficiencies.”
Flow International Corp., 800/446-3569, http://flowwaterjet.com/
Food Process Systems Inc., 608/592-7793, http://fpsinc.net/
