How Walker helped the manufacturing team at Woodgrain Composites reduce their equipment replacement costs by 70%
Woodgrain Composites, Island City, Oregon
Same reliable product, more consistent additive distribution.
Woodgrain Composites, a particleboard manufacturer nestled at the foot of the Blue Mountain range in Oregon has been producing composite panels for over 50 years. Consistent additive distribution is a key element in their manufacturing process. But with regular use over time, the resin and wax spray nozzles used on their application equipment were wearing quickly, causing variances in the distribution of coatings. Not only that, but with their nozzles being sourced overseas, their replacement supply was coming in at a great cost coupled with inconvenient lead times.
What started as a partnership to test and solve for one challenge evolved into discovering and solving for secondary business challenges.
Working hand-in-hand with the Walker labs, Woodgrain was able to determine best practices for additive distribution and the need for a systematic nozzle replacement plan. Walker worked with them to find a custom solution to get the consistent results they needed, and sourced a local supplier to help decrease their replacement costs.
Walker's scientists conducted a series of spray tests to determine the variance in performance and optimum nozzle lifespan that would ensure consistent coverage over time. This provided Woodgrain with a clearer understanding of the process and data to support the effectiveness of the nozzles over time.
Meanwhile, Walker's customer service team, equipped with their own expertise in application equipment, provided consultation and connected Woodgrain Composites with a local machinist who was able to replicate the brass nozzles at one-third of the cost, in a fraction of the timeframe.