"Thrushed" to the Front of Assembly Line

When a critical component of any manufacturing process decides to fail, the idle downtime can cost thousands of dollars depending on the application and process, putting a strain on a company’s bottom line. 

That was the case recently for an Indiana-based biopharmaceutical contract manufacturer specializing in complex injectable formulations that include liposomal drug delivery technology and PEGylation. 

On noon Friday, one of the company’s production lines came to a screeching halt due to the failure of a shell and tube heat exchanger, a critical component that regulates their cooling process. After examination the customer determined that it needed a replacement unit, but time was money and every minute translated into lost dollars for the company.

They turned to Affiliated Steam and Hot Water, one of the largest distributors in the Midwest for steam and hot water equipment. Working with Affiliated’s Kris Long, a sales engineer assigned to central / western Indiana, and his inside heat transfer specialist, Neil Vogel, they contacted the Thrush Company, Inc. located in Peru, IN for a solution. Since heat exchangers are not typically a shelf item, Thrush would have to manufacture the required sized unit by midnight that evening.  

Working with Erin Edwards, Sales Manager, and Aaron Schipper, Director of Engineering of Thrush Company, Vogel specified a new four pass u-tube heat exchanger with 1/2" OD copper tubes and Teflon baffles (because they were in stock) measuring 12" diameter x 60" long. 

Thrush Company went quickly to work designing and manufacturing the unit because time was of the essence. During manufacturing, Schipper video-texted Vogel showing the CNC machine cutting the tube sheet, which is used to hold the tubes inside the heat exchanger. The unique video eased everybody’s nerves knowing that the customer would be able to pick up their new heat exchanger by midnight.

“The fact that Thrush Company didn’t start the manufacturing until 5:00 p.m. and kept staff working until midnight to complete the heat exchanger, all in an effort to take care of a customer with an emergency situation, shows what a superb company they are,” said Rick Lee, president of Affiliated Steam and Hot Water.

The end result was a job well done, a team effort by all parties, and a customer relieved to get their manufacturing process up and running again.

5/26/2011 | 605 Views