How American Heavy Plates Cut Lead Times With Magswitch High-Heat Magnetic Lifting Systems
How American Heavy Plates Cut Lead Times With Magswitch High-Heat Magnetic Lifting Systems
Case study: safer handling of hot, long, and thin plates with electro‑permanent magnet technology
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Executive Summary
- Challenge: Handle thinner 2 inch plate up to 500 inches long and move hot plate sooner without compromising safety.
- Solution: Two fixed-beam high-heat magnetic lifting systems from Magswitch featuring electro‑permanent magnet (EPM) technology.
- Impact: Earlier hot-plate handling, shorter lead times, improved yields, and a failsafe magnetic hold that does not depend on continuous power.
About American Heavy Plates
American Heavy Plates (AHP) is a hybrid rolling mill, processor, and service center in Clarington, Ohio. Built on the site of the former Ormet aluminum mill, AHP restarted operations after a full facility overhaul and has invested heavily in new equipment to expand its capabilities and product mix.
The Handling Challenge
AHP’s growth plan required producing thinner plate (down to 2 inches) and longer plate (up to 500 inches). Traditional electric magnet lifters that worked well on 3 inch and thicker plate were not rated for the length and temperature demands and risked peel-off on thinner gauges. In thermal processes across the mill and service center, temperatures often exceed 1,000 °F, where legacy systems were out of spec.
The Magswitch Solution
To meet the new handling window, AHP implemented two fixed‑beam high‑heat magnetic lifting systems engineered by Magswitch. The systems use electro‑permanent magnet (EPM) technology that requires electricity only to engage or disengage the magnet and maintains a magnetic hold without continuous power. Each beam provides a 25‑ton lifting capacity with a 3:1 safety factor and is ASME compliant. A spreader‑beam layout with rare‑earth magnet modules at each end delivers stable, one‑at‑a‑time plate pickup with consistent, repeatable force.
- High‑heat rating up to 1,112 °F (600 °C)
- Heavy‑duty wireless remote for operator convenience
- Adjustable power levels to optimize for varying thicknesses and dimensions
High‑Temperature Handling, Done Safely
In rolling operations, steel heats to ~2,350 °F and becomes magnetic as it cools. With the new lifters, AHP can begin moving plates as soon as they reach roughly 1,000 °F, significantly earlier than before. The failsafe EPM design means that even in a power loss event, the magnets stay on, safeguarding personnel and product.
Lead Time Advantage
By moving hot plate sooner and stabilizing long, thin product handling, AHP accelerates material flow through the plant. This supports its just‑in‑time model, enabling rapid turnaround on custom plate and parts.
“We can, within days, process plates and/or parts to exactly what a customer wants. No one in the industry is focused on this kind of speed.”
— Jeff Thompson, Executive Vice President of Operations, American Heavy Plates
In one example, a chemical processor facing critical downtime was quoted up to four weeks elsewhere. AHP shipped parts within 24 hours and delivered additional plates within the next four days.
Yield Gains and Cost Control
With reliable handling out to 500 inches, AHP can roll full‑length plates instead of two shorter lengths. That eliminates an extra set of heads and tails and reduces scrap on the mill’s most expensive input—raw material—translating to better yields and a healthier bottom line.
Key Specs at a Glance
| Parameter | Value |
|---|---|
| Lifting capacity | 25 tons per system |
| Safety factor | 3:1, ASME compliant |
| Technology | Electro‑permanent magnet (EPM) |
| High‑heat rating | Up to 1,112 °F (600 °C) |
| Plate thickness handled | Down to 2 inches |
| Plate length handled | Up to 500 inches |
| Operator controls | Heavy‑duty wireless remote, adjustable power levels |
Ready to Modernize Your Plate Handling?
Explore high‑heat magnetic lifting systems and EPM solutions from Magswitch.