Challenge: A customer asked Skolnik to manufacture a 55 Gallon Steel Drum that meets exacting specifications for the type, number and placement of four fittings in the drum top head and body.
Top fittings had to be a specific diameter with a highly unusual tight tolerance of ± 0.030". Also, they were inverted 3/4" fittings that needed to be exactly 180 degrees apart. In addition, there were two 2" standard orientation body fittings that had to be exactly 180 degrees apart on the body and at a critical distance from the top of the drum ± 1/4". The tolerances alone were of such critical dimension that no other industrial packaging manufacturer would even attempt to produce these drums. In addition to these critical tolerances, all four flanges had to align linearly.
Solution: To address these precise, multiple requirements, we enlisted the creative talent of our manufacturing, production and machinery design departments. Thorough review of our machinery settings and the purchase of new digital micrometers allowed us to address and confirm the tolerance issues.
Next, it was an engineering/maintenance challenge to develop a method to prevent slippage during the seaming process. Since Skolnik engineers brainstorm daily to meet customer needs, they are accustomed to developing innovative solutions. Here, they devised a way to seam the heads onto the body while both parts were rotating, and perform a welding operation prior to seaming. To achieve this, they developed a robust welding fixture that captured multiple degrees of freedom. This was accomplished by containing the assembly in a free form, which allowed for multiple position spot welding between the head, fittings and the drum body.
Results: Each unique requirement was executed flawlessly, and our customer learned what sets Skolnik Drums apart from commodity drum manufacturers—a willingness to do whatever it takes and find creative solutions to meet unusual requirements.Back to Case Studies