Ceramic Brakes vs. Regular Brakes: Does it Matter in Industrial Vehicles?

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The American industrial and manufacturing industry is thriving. Even in today’s economic climate, the manufacturing industry has directly employed over 12 million workers and is generating consistent revenue for the US economy.

To remain efficient, though, industrial plants must have the most efficient and effective equipment on the market. This means looking into new trends in braking. Ceramic braking is one of the newest and most coveted braking technologies out there, but what exactly are ceramic brakes?

Read on to answer this question and learn the difference between ceramic brakes vs. regular ones.

How Do Regular Brakes Work?

Generally, there are two types of regular industrial brakes: drum brakes and disc brakes. Both of these brakes rotate and use friction to slow down or stop the running machine that they’re attached to. Drum brakes have a hollow area that presses outward and around the wheel when the brakes are turned on, causing the machine to stop.

Today in discussing ‘regular brakes,’ our focus is on disc brakes. Disc brakes have a semi-metallic pad that presses down onto the brake disc, causing the machine to slow and stop. This metallic pad, known as the disc, is in the front of the brake’s wheels. It relies on hydraulic oil to run efficiently, so you’re going to need to change out the oil frequently.

Regular brakes are an incredibly affordable technology, and since they’ve been used for decades, you know what you’re getting.

What Are Ceramic Brakes?

Similar to disc brakes, ceramic brakes stop a machine with a brake pad that presses down onto the brake disc. However, this brake pad is made from ceramic instead of the semi-metallic metal material that disc pads use.

This is a relatively new technology, but it’s been gaining traction (no pun intended) very quickly. They’re made of soft copper combined with ceramic to make the brake work without putting too much pressure on the machine. This means that they’re a lot quieter than regular brakes and create less regular rotor wear and tear.

Ceramic Brakes vs. Regular Brakes

The main difference between ceramic vs. metallic brake pads is the material used to press down on the machinery’s wheels.

If you’re operating in conditions like extreme cold or heat, you need to use semi-metallic brake pads. This is because ceramic ones don’t hold up in these extreme conditions and will begin to melt and stop functioning.

However, if there are no extreme conditions, ceramic brakes may be the way to go since they’re less likely to overburden our machinery with pressure and rotor wear.

It’s interesting to note that ceramic brake pads can also be used in cars. Check it out!

Get Industrial Brakes Today

While selecting the correct industrial brakes for your machinery can be difficult, you’ll be fine as long as you do your research on all your options and choose the best one for your specific needs.

Now that you know the difference between ceramic brakes vs. regular ones, it’s time to begin selecting brake and clutch machinery for your industrial plant. Click here to contact us and discuss your specific needs with a professional. We’ll be more than happy to give you a quote and discuss the pricing for your equipment as well.

Sintered vs. Organic Brake Pads: What’s the Better Option for Your Construction Business?

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In just one year, the American manufacturing industry can generate $2.33 trillion in revenue. That’s nearly 12% of the US’s GDP, so there are clear statistics as to how vital this industry is to our economy.

To continue to thrive, manufacturing plants need to continually update the methods they use and the tools they have to maximize output. This means having the correct industrial brakes and clutches for their needs.

Sintered vs. organic brake pads is an important distinction to make when choosing the right brake pads for you, so read on to learn more about both these options!

What Are Sintered Brake Pads?

Sintered brake pads are made of various metallic particles fused together. This is done by applying heat and pressure to the particles and ensuring that they mold together effectively and intricately. This process is, as you may imagine, called ‘sintering,’ and the final product is incredibly resistant to friction.

This resistance is the reason that sintered brake pads are the most widely used type on the market. All the friction generated will go into stopping the machinery rather than being absorbed by the brake pads, meaning that the pads are highly effective. Furthermore, your industrial machinery will stop efficiently without wear and tear, harming the brake pads.

How Do Organic Brake Pads Work?

Unlike sintered brake pads, organic ones are combined with resin. They’re a mix of fibers and fillers, not entirely made of metallic parts. They’re durable but slightly less so than sintered brake pads. Also, they are ideal for smaller machinery as well as machines that aren’t operating in extreme hot or cold conditions.

The main advantage of organic brake pads is they’re a lot smoother than other brake pad types. While sintered brakes stop the machine more abruptly, organic ones are more gradual.

Sintered vs. Organic Brake Pads

Sintered brake pads are louder than organic ones because they create more friction. If you value low noise levels, you may want to try organic brake pads. However, since sintered ones do have more friction, they’ll be able to stop your machinery more quickly than organic ones would be able to.

Organic brake pads are also pretty environmentally friendly. You don’t need to go through the energy-sucking sintering process to create them, and all of the materials they’re made from are recyclable. This is great, but you will sacrifice some durability. Just something to think about!

Also, the sintered vs. organic distinction is also made with motorcycle brake pads. This shows that both of these brake pad types can operate on machines of any size.

Get Cracking!

Running a manufacturing plant can be a challenge. It’s much easier when you have the appropriate equipment to get the job done efficiently.

Now you know the difference between sintered vs. organic brake pads and have an idea of which is the right choice for your industrial plant. It’s time, then, to get the brake pads that will work best for you at an affordable rate. Click here to contact us with any questions you may have on industrial machinery and to get an estimate of how much it will cost you to get the right clutches.

What is a Compactor and How Do I Choose the Right One?

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Did you know that the total generation of municipal solid waste in 2017 was 267.8 million tons? Are you looking to cut down on the waste your company produces? 

In this article, you’ll discover what a compactor is. You’ll also learn how to choose the right one. Read on to find out why it’s so crucial to have in your business, and how it’s so beneficial. 

What Is a Compactor?

A commercial, construction, or industrial compactor is a machine that collects waste into a container. Operators first place the waste at ground level from a loading dock into a chute on the machine. The waste builds up inside the container until the operator does a compaction cycle. 

A compaction cycle is where a platen which is attached to a hydraulic ram pushes the waste into the one end of the container. This waste is then crushed and smaller in size. 

You can also choose from road compactors, soil compactors, and earth compactors. Earth compactors are popular in industrial construction zones. 

Soil Compactors

The soil has four components: granular rocks, minerals, air, and water. Soil compactors work by kneading, vibrating, or compressing soil to increase density and remove air pockets. It’s vital that soil compactors are appropriately used because they can cause severe or fatal injuries. Always ensure you’re using proper operating instructions and receive hands-on training for the soil compactors you utilize. 

Make sure you follow the manufacturer’s maintenance schedules and inspect equipment before using your compactor. Always use guards on pinch points and moving parts. Have backup alarms, so pedestrians are aware of the compactor moving. 

Without using soil compaction, you can have pipe leakage, breaks, slab cracks, and foundation erosion. If you use a soil compactor for extended use, you’re more likely to have vibration syndrome. This causes damages to nerves and finger circulation. 

Symptoms of this include blanching, pain, and numbness. Read instructions for vibration level ratings and maximum use. Always have a straight back and proper posture while using a soil compactor. 

Road Compactors

A roller-compactor, also known as a road roller, is used to compact asphalt, concrete, gravel, or soil. It’s used in the construction of foundations and roads. 

Pneumatic Rollers

Pneumatic rollers have rubber tires. They’re used for the compaction of coarse-grained soil, such as in sub-grade pavement projects. Rollers use the weight of the vehicle to compress the surface. The flexibility of pneumatic tyes allows the roller to operate on uneven ground.

Vibrating Plate Compactor

It’s used to compress different types of gravel and soil. They use a heavy steel plate at the base and resembles a mower. 

Plate Compactor

A plate compactor is best used for creating a level grade. A jumping jack compactor has a smaller foot. The jumping jack compactor is mainly used to compact backfill in trenches for gas supply pipes or water. 

Determining What a Compactor Is

Are you ready to get started on your next construction project and want to ensure you have all the necessary equipment? Check out our products today for your construction needs. 

 

How Do Emergency Brakes Work in Construction Vehicles?

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If you’re one of the two million farmers in the US or regularly work with heavy farming equipment like tractors for any reason, you’re lucky if you’ve never had to use your emergency brakes. Still, you likely know that they’re there for a reason and feel much more comfortable knowing that you have a failsafe in case of an emergency.

You’ve also likely wondered how emergency brakes work before, and it’s quite an interesting process. There’s an intricate cable system that works to stop the machine, but there’s more to it than that. Here, we’re going to discuss brakes and clutches that farming machinery uses for emergencies, so read on to learn more about the equipment you love.

What Are Emergency Brakes?

On pretty much any piece of equipment, be it industrial or farming-related, hydraulic brakes are installed as the main braking system for the machine. Generally, these brakes work well, but there are some situations in which they may suddenly fail.  That’s where emergency brakes come in!

These caliper disc brakes are attached to the tractor or other equipment in a different location than the main brakes and are used as a failsafe should the hydraulic brakes stop working. Generally, they’re made from one cable that connects to two-wheel brakes that then connect to a mechanism that can pull them to a stop. Pull a manual switch, and the brakes will take action.

How Emergency Brakes Work in Construction Vehicles

In the most basic sense, the emergency brake bypasses the use of the hydraulic brake to lock the machine’s wheels in place and inhibit movement. The cable system discussed above is connected to the emergency brake lever, which allows for the driver of your tractor or other large equipment to pull a lever and trigger this cable to be pulled. Ultimately, this will put enough friction on the wheels to stop the machine.

In machines that have drum brakes rather than rotor ones, the cables will put pressure in another area as well. This area is another lever that holds the shoes on the wheel of your machinery. This system stops the wheels from continuing to move and stops the machine as quickly as possible.

Learn More About Emergency Brakes

While you hope never to need to deploy your emergency brakes, it’s essential to maintain them to the best of your ability. After all, you never know when you might need them as a failsafe so that both you and your equipment can keep going strong.

Now that you know how emergency brakes work on heavy farming equipment, it’s time to look into getting brake and clutch accessories to make your machinery run more smoothly. Click here to shop for accessories that will ensure that this happens at an affordable price.

How to Tell If a Clutch is Slipping

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The industrial manufacturing industry currently employs 12.82 million American workers, and that number is only growing. Over the next ten years, it’s estimated that 4.6 million manufacturing jobs will be needed in addition to the pre-existing ones.

For this job growth to continue, however, it’s essential to keep industrial plants up and running to their maximum capacity. This means ensuring that the brakes and clutches on each piece of machinery are operating well. Fortunately, there are some ways that you can make sure that this is the case in your plant.

Learn how to tell if the clutch is slipping off of one of your machines and what to do if you discover that it is.

How To Tell If Clutch is Slipping

There are a couple of reasons that a clutch commonly begins to slip. Read on to learn the two most common ones and the signs that they’re happening. We’ll also talk about how to get to the root of these common issues that cause clutches to slip, so you can continue to run an efficient plant.

Worn Friction Plate

One of the most significant signs that a clutch might be slipping is high engine revving when the machine starts up. When the clutch is deployed and engaged on a piece of machinery, it’s meant to rev a little bit before slowing down. However, the engine of a machine with a slipping clutch will rev much higher than usual and won’t stop.

This is the sign that your clutch is slipping due to a worn friction plate. Usually, this issue is accompanied by a burning smell. If this burning smell is more intense when your engine is revving, that’s a surefire sign that your clutch is slipping for this reason.

If you have a worn friction plate, you’re almost certainly going to need to replace it. Call in a professional if you think they can help by taking a look at it, but chances are your friction plate has run its course.

Problems With Clutch Surface

Another sign that your clutch is slipping is that it makes a strange sound when functioning. These sounds include high-pitched whining or squealing, repetitive clanking and clicking, and hissing.

Beyond the noise that an industrial clutch usually makes, it should be pretty quiet and smooth-running. This could be a simple fix- your clutch service may have rust on it that you can scrape off or have a small sliver of wood, sawdust, or metal stuck in it that can be removed. More likely than not, though, it’s slipping, and you’ll have to pull it apart to discover the source of the issue.

Shop Industrial Brakes and Clutches

While a slipping clutch could be disastrous if you don’t catch it, there are fortunately easy ways to tell if this is happening and repair it quickly.

Now that you know how to tell if the clutch is slipping, it’s time to look into some of the best deals on industrial brakes and clutches. If you think you need a new clutch or a professional to take a look at your slipping one, contact us. Our professionals will answer your questions to ensure that your industrial plant is running at maximum efficiency.

 

What You Should Know About a Self-Inspection Checklist

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In 2019, the Occupational Safety and Health Administration (OSHA) found at least 6,010 safety violations at U.S. businesses for improper fall protection. Every violation puts workers at a greater risk for fall-related injuries.

The scary thing is, that’s only one of the top 10 most common OSHA violations—it’s not a total. It’s possible that many more violations just went unnoticed. 

So, how can you prevent OSHA violations and keep your employees safe? 

Luckily, the OSHA inspection checklist can be a big help. Read on to learn about the checklist and how you can create a self-inspection process for your workplace. 

What is an OSHA Inspection Check List?

OSHA inspection checklists help you keep track of the safety compliance at your facility. Instead of a master checklist, there are separate checklists for each category of safety regulation. These include fire protection, hazardous chemicals, materials handling, and much more.

If your workplace gets an OSHA inspection, the auditor will evaluate your facility based on its safety regulations. Your goal is to pass the inspection with few or no errors. 

Using OSHA checklists to do your own safety checks will help you pass inspection and keep your workplace safe. 

How to Create an OSHA Safety Check Process

The exact checklists you need will depend on the type of business you have. You can find specific checklist examples in the OSHA Small Business Handbook. You won’t need to use every checklist, only the ones that are the most relevant for your industry. 

Your checklists should focus on the aspects of your business that are the most hazardous. For example, chemical companies should focus on hazardous chemical handling checks since it’s a risk. 

You should also list the regulatory citation codes for each step. If there’s a problem, look up the official OSHA rules for a solution. 

Also, plan to do safety checks at scheduled times (daily, weekly, monthly, or quarterly). If you build regular safety checks into your schedule, you’ll be more likely to stay compliant. 

Benefits of Safety Self-Inspections

No matter what industry you work in, it’s essential to do regular self-inspections for the safety of your employees and your workplace.

You’ll be able to catch potential hazards like ventilation issues, chemical leaks, or slip hazards. Plus, you can check if your employees are up-to-date on their safety protocol training. 

When you have a safer workplace, your employees will feel safer, and they’ll do better work. 

Safety self-inspections can also prevent unpleasant surprises if you get audited by OSHA. If you’re compliant, you won’t face OSHA violation fines. Depending on your insurance carrier, doing safety self-checks can even lower your premiums.

Make Your Operation More Compliant Today

If you need to solve compliance issues, set up a self-inspection process using OSHA inspection checklists.

Regular safety checks are essential, but you might run into machinery problems in the process. Luckily, at Kor-Pak, we offer replacement parts for heavy machinery, as well as some maintenance. 

If you’re not sure what your business needs, contact us today. Our representatives look forward to answering any questions you have. 

 

What Are Overhead Crane Training Requirements? Things to Know to Pass

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Do you want to be an overhead crane operator? If so, you should know what to expect from the role. Overhead crane operators lift and move materials, products, and machines. This requires knowledge of rigging, proper operation, maintenance, and signaling.

To gain the knowledge you need for the role, every overhead crane operator must undergo training. The typical training is only a few days long and includes practical lessons and classroom theory.

Most employers provide this training. You may also take different tests through the National Commission for the Certification of Crane Operators (NCCCO).

What can you expect from overhead crane training? Here are the overhead crane training requirements you need to pass.

Physical Ability

Overhead crane operation is a physically demanding job. Most operators are often on their feet. When you are sitting, you’re using your arms and legs to control machines, tools, and equipment. Most of the work is done at great heights, and you’ll work with potentially dangerous machinery.

The working conditions can get pretty extreme, including exposure to loud noises.

To ensure you can handle the conditions, you must prove you can physically handle the job. All students require a medical examination and obtain a certificate from their doctor that shows they fit all the standards needed by the Department of Transportation.

Safety Training

The OSHA requires overhead crane safety training. When you pass the training, you receive certification. This certificate lasts three years, and re-certification is required.

Most of the safety training includes pre-operation inspections and signaling. Some of the inspections you’ll learn include load hook and safety latch inspection, control pendant inspection, walkway and site inspections, and load-bearing rope checks.

Most pre-operation checks start with checking controls, operating the crane in every direction, slowly raising the load block, checking the emergency stop button, and ensuring the wire rope is spooling correctly. This ensures you don’t endure machine failure and other problems.

For operation safety, you’ll learn how to lift each item slowly to maximize safety. You’ll know how to identify obstacles and move objects without abrupt movements.

You’ll also learn basic safety information, such as keeping hands away from pinch points.

In addition to these necessary training tools and inspections, you’ll learn what to do in case there’s an emergency.

Job Performance

Overhead crane operators are required to know the proper operation, signaling, rigging, and maintenance of the overhead crane they’re using. Here are some of the complex tasks you’ll learn:

  • Modes of operation
  • Pre-operation inspection
  • Wire rope construction design, uses, and inspection
  • Reeving
  • Gross and net capacity
  • Crane work areas
  • Capacity reduction
  • Operator and rigger responsibilities
  • Knowing hand signals
  • Lift problems
  • Site conditions and inspections

You’ll learn these topics through a combination of classroom and hands-on training.

Know the Overhead Crane Training Requirements and Earn Your Certification

If you want to be an overhead crane operator, you must complete the mandatory training courses and achieve your certificate. These overhead crane training requirements will help you prepare for the training.

Do you have an end of life crane or another piece of equipment that requires a professional inspection? Take a look at our overhead crane inspection services.

Industrial Brake Relining

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No matter how powerful your vehicle is, there’s one thing even more important than its engine: its brakes. This is especially true for large industrial vehicles where failing brakes can cause more than just a fender bender. 

To keep your brakes in tip-top shape, you will occasionally need to reline them.

Brake relining might seem like a complicated process that requires professional assistance. But, you can become an expert in brake relining yourself! 

Read on for everything you need to know.

What Is Brake Relining?

Brakes are a relatively simple mechanism. When you press the brake, the brakes apply pressure to the wheel, bringing it to a stop.

However, metal-on-metal doesn’t stop very quickly, so to increase braking power, nearly all braking mechanisms use some sort of non-metal liner to add more friction. Note: electromagnetic brakes typically will not use a brake liner.

This is a liner that is often made of rubber, Kevlar, or ceramic, but other non-metal materials may be used.

This liner is meant to be replaced regularly to maintain the proper operation of the brakes. Here’s how to do it. 

The Step By Step Guide

First, take off the brake drum. Examine it for any excess damage. If it is damaged, you will need to replace more than just the liner.

Inspect the brake liner. Look for signs of uneven wear, as this can point to more significant issues with the brake drum. Also inspect bushings, rollers, and pins. If one side is more worn than the other, your brakes will need to be recalibrated in addition to being relined.

Remove the old liner and remove the old grease and adhesive from the brake drum. You can use a powerful debonding agent or high heat to do this. 

Remove the bushings, rollers, pins, and springs along with the old liner. 

Clean the brake drum surface where the lining will be bonded. Any debris will get in the way of your liner adhering well to the drum, so be thorough.

Prepare the new liner. Make sure it complies with all guidelines laid out by your brake manufacturer and is the proper size. 

Apply the bonding agent to the new liner and set it in place. 

As you replace the liner, pay attention to the fit. Look for signs of warping or stretching. Pay careful attention to how it fits the anchor pin and roller pins. If it is stretched or warped, you will need a different size. Inspect all hardware to ensure it will operate properly.

Make any necessary adjustments to assure proper fit, then road test the vehicle. Make several stops. After the brakes have cooled, inspect them to make sure the brakes are correctly adjusted.

Get Ready to Stop

After following this brake relining process, your brakes should be ready to go—or stop, instead. 

If you need additional help finding the right parts or installing them, don’t hesitate to contact us. We’d love to help you get your equipment back in commission. 

How Do Electric Brakes Work in Industrial Vehicles

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If you were not aware, industrial vehicles use a different type of braking system known as electric brakes. They are typically standard in cranes and trailers. An electronic brake is similar to hydraulic brakes in cars. 

Keep reading to learn more about how electric brakes work in industrial vehicles.

Brake Controller

Every electric brake has and needs a brake controller. The controller is what modulates the electrical current that is sent to the electric trailer brake anytime the brake pedal is pressed. 

The controller is connected to the stoplight switch and the vehicle battery. When you depress the brake pedal, the controller is energized.

You have two options when it comes to a brake controller:

Proportional Controllers

This type of controller is also known as an inertia controller. Proportional controllers have a mechanism that determines how quickly the tow vehicle is stopping, and it modulates the power to the brakes in proportion to how fast the vehicle is stopping. The brakes are applied at the same rate and at the same time as the tow vehicle brakes. 

Time Delay Controller

This controller option is not automatic, like proportional controllers. The controls have to be adjusted to compensate for the weight of the vehicle the moment the brakes are pressed.

If a time delay controller is not adjusted correctly it can lead to too much stopping assistance or too little. Either way, it can cause an accident or hurt the driver.

The Mechanics Explained

Now that you know that there is always a controller present with electric brakes, let’s go over how exactly they work. There is an electromagnet in the backing plate that has two conductor wires that tap directly into the trailer wiring. 

When the electricity is on, the brake magnet magnetizes, and it is attracted to the drum face. Once it makes contact, the friction makes it rotate, which causes the actuating arm to move, which then pushes the shoes out against the drum. Once those shoes come in contact with the inside of the drum and press on them, it prevents the hub and wheel from spinning.

How Does Electricity Reach the Brakes?

There is an electrical connection on the industrial vehicle (crane, trailer, etc) that plugs into the connector on the vehicle. There are electrical wires that run from the trailer connector to each brake on the axle and the trailer lights to complete the circuit.

As soon as the driver hits the brakes, a current of electricity goes from the brake control to the vehicle. Then the brake control sends a current back to the vehicle and activates the electrical brakes.

Feeling Like an Electric Brake Pro?

Now that you are aware of how an electric brake works in industrial vehicles, you can ensure that you are safe next time you are using a vehicle with an electric brake. Electric brakes might sound more complicated than regular vehicle brakes, but now that we have explained in further detail, we hope you are feeling confident next time you are handling any industrial vehicle that is equipped with electric brakes.

If you need electric brake parts, we can help you find what you need. Please contact us today we are ready to help you!

4 Thruster Brake Benefits

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Despite a decrease in overall production and sales, the steel industry still produced a whopping $17.4 million dollars in 2019 revenue. This is only one industry that uses industrial brakes in its day-to-day operations, with other metal manufacturing plants also regularly using these brakes. No matter how you look at it, industrial brakes and clutches- including thruster brakes- are here to stay.

If you’re looking to increase production value at your plant, look no further than thruster brakes. Read on to learn some of the essential thruster benefits so that your business will be booming in no time.

1. They’re Affordable

Thruster drum brakes are an incredibly affordable purchase for your industrial plant, especially considering how much use you’ll get out of them. While there are various financing options for your thruster, you can contact us to get a quote as to how much it’s going to cost you!

2. They’re Versatile

Thrusters are great because they can be used in basically any manufacturing conditions. They can survive high temperatures on their own, but this is made even more possible with the addition of high-temperature kits or silicone fluid.

They can also be used with variable frequency drives since the setting of the brakes can be put on a timer. The operator can also add set and release switches to the thruster, making its operations automatic. This saves you the stress and hassle of manually operating such a large and potentially hazardous piece of machinery.

3. They’re Easy to Maintain

Despite their size and versatility, thruster breaks are incredibly easy to maintain.

These machines consist of two essential parts: a hydro-electric actuator/thruster and the movement. Occasionally, you’ll need to do things like clean and recondition the movement or change out the lining of the brake shoes.

These parts can both be professionally maintained regularly at a meager fee, and they can be refurbished to be like new after even years of use. The fact of the matter is that thruster brakes were explicitly designed for easy maintenance, and they live up to that reputation.

4. Part Replacement Is Easy

When you have a thruster that you’re operating, it’s only natural that it will go through some regular wear and tear. Parts that help the machine operate are going to need to be replaced on occasion, meaning that you’ll need to order new ones. Items like brake wheels, shoes, reline brake shoes, enclosures, limit switches, self-adjust mechanisms, and pins will need to be monitored and replaced at intervals.

We at Kor-Pac sell all the parts and accessories you may need for your thruster on our website. This makes buying new parts incredibly simple, and you won’t even need to pay two shipping fees if you order your parts at the same time!

Get These Thruster Benefits Today

 While selecting the correct machinery for your industrial needs can be a challenge, thruster brakes can make your job a lot easier.

Now that you know the top thruster benefits for your manufacturing plant’s brake needs, it’s time to get shopping and get a brake. Click here to learn more about our selection of industrial brakes and clutches so you can make the decision of which one is best for you.