When it comes to plasma cutting systems these days, there are a lot of options on the market, but making the right choice can be a challenge for manufacturers. Israel Gonzalez offers some advice.
Today, metalworking manufacturers have the luxury of options when it comes to selecting a suitable plasma cutting system for their operations. However, with globalisation and a competitive business environment, manufacturers have to grapple with demands for high-quality products delivered within a short period of time, while balancing upfront investments and long-term operation costs.
With all these challenges to juggle, it may seem like an easy choice for companies to opt for low-cost cutting systems. However, to ensure their products are of high quality and that they remain competitively priced, manufacturers must consider the type and volume of cutting that needs to be done, and determine specifications that can impact the cutting applications, productivity, and accuracy requirements.
So, the question is: how can one determine if a plasma cutting system can meet your production needs while keeping costs low? Here are three important considerations that manufacturers should factor into their decision.
#1 – Is the system a proven solution?
In general, the most reliable plasma cutting systems are manufactured to ISO standards and are adequately tested. Such systems are engineered and built under strict specifications and with quality materials, which make them truly durable. These systems tend also to perform better in terms of duty cycles. However, there are discrepancies in how tests are performed in the market.
Manufacturers should take note that systems that seem to perform better on shorter test cycles may bring about longer-term implications, such as increased downtimes during production. Rigorous testing often means stretching the performance of the cutting system to troubleshoot and improve the system’s design. For example, if the reported duty cycle is 60%, a five-minute and a ten-minute test duration would result in a difference between pausing cutting operations for a break after every three minutes or six minutes.
Another mark of a proven and reliable solution is the length of the warranty. Plasma cutting manufacturers who stand behind their products often offer a longer warranty period and cover more parts. This way, end users can be assured of better coverage and fewer issues in the long run.
#2 – How easy is it to operate?
While there may be a plethora of options, some plasma cutting systems are easier to use than others. An intuitive system allows an experienced operator to complete a job more efficiently. It also enables new employees with little or no experience to achieve good results with simple training. Most local plasma systems require considerable skill, which requires months of training, since the operator has to float the torch over the metal piece (otherwise known as ‘holding a stand-off’). A lack of experience may result in shaky cuts on the parts, which then require more secondary processes to perfect.
Over the years, advanced plasma cutting systems with countless inventions and technological breakthroughs have been developed to address this challenge. One such solution is Hypertherm’s Powermax system, which offers drag cutting. This innovative technology allows operators to rest and drag the torch right on the metal due to the uniquely designed shielded consumables. Business owners can save on time and cost for training, and avoid problems with absenteeism, which often cause delays or fluctuations in quality. Operators, regardless of their experience level, can simply drag the torch along a straight edge or template, get the jobs completed efficiently, and produce quality products, all while ensuring projects stay on schedule.
The simplicity of these advanced cutting solutions also offers users the added advantage of superior safety measures, which translates to a lower risk of injuries, reduced damage to the nozzle or torch, and a safer work environment for operators.
#3 – Can it help keep operating costs low?
Manufacturers should finally consider the operating costs. It is important to note that while the initial cost of acquisition may be lower for some plasma cutting systems, one should not overlook the consumable costs involved before finalising a decision on the system to invest in.
Consumable life for plasma cutting systems can vary significantly from one brand to another. With longer consumable life, downtime for change-outs and overall spending on consumables can be greatly lowered. Many brands market their consumables at a lower cost, but these simply do not last during cutting operations. As such, users would end up changing the consumables more often in the span of an operation. In some cases, Hypertherm’s patented consumables are proven to last up to 80% longer than these brands.
Making your decision
The choice of a plasma cutting system is important for businesses to truly achieve their productivity potential. With the availability of advanced solutions in the market, metalworking manufacturers must be clear about the system’s reliability, ease of use, and long-term costs before deciding which brand or system to invest in. With a robust and thoroughly-tested solution like Hypertherm’s Powermax, companies can become better equipped to navigate the competitive business environment and optimise their cutting operations.
Israel Gonzalez is a Distribution Sales Director at Hypertherm Asia.