Grate Plate Savers

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Grate Type Cooling Beds

Discover the distinct advantages of the Grate Plate Saver®

• Solve the scratching problem with grate type cooling beds.
  
• Lower maintenance & wear.
  
• Use existing equipment.
  

Your cost-effective solution to the problems of slide over grate systems

Plesh Industries is proud to introduce the Grate Plate Saver®, a patented insert system designed specifically for plate mills with grate type cooling beds. Grate Plate Saver® offers you a simple, cost-effective solution to cooling bed problems such as plate bottom side damage, plate edge damage, excessive grate wear, and high maintenance and repair costs.

The Grate Plate Saver® system features a precision manufactured assembly designed to insert into existing cooling bed grates, allowing standard grates to be adapted with rollers. In many cases, there is no modification required to the existing grates.

Discover the distinct advantages the Grate Plate Saver® delivers for your plate mill operation.

Higher product quality scratch-free plates

With the unique Grate Plate Saver® system, rollers support the plate as it transfers across the cooling bed, eliminating plate contact with the grates. The roller system also reduces edge damage to plates.

• Scratch-free plates can be sold at a higher margin
  
• Offer plates with two sides prime
  
• Reduces repair to plates no hand grinding to smooth out scratches
  

Reduced operating costs lower maintenance & wear

The supporting rollers of the Grate Plate Saver® prevent the plate from contacting the grate to totally eliminate grate wear. The rolling friction required to transfer the plates is much less than current systems, further reducing component wear.

• Reduces replacement of grates because of wear
  
• Increases chain and related transfer component life about 250%
  
• Reduced demand on drive system i.e. motors, gear boxes, etc. reduces power consumption
  
• Reduced shifting of grates in systems where the grates are not securely fastened to the sub structure, friction can cause the grates to shift, causing them to fall into the basements or have portions protrude above the top surface of the cooling bed. This causes plate and grate damage that may result in lost production.
  

Lowest initial investment utilize existing equipment

Grate Plate Saver® is an extremely cost-effective solution compared to other systems utilized by some plate mills to correct cooling bed problems. The initial cost is relatively low without extended installation downtime associated with systems such as walking beam tables, chain transfer, powered rollers, or idler rollers.

• Grate Plate Saver® is designed to be installed into your existing grates
  
• The existing grates are used as a support structure for the inserts
  
• Any current spare grates can be utilized
  
• Often old grates that are beyond normal use can be fitted with inserts for re-use
  
• Inserts can be installed gradually during several regular repair turns, eliminating the need for a major equipment outage
  

From Design to Manufacturing...

Our engineers will work with you to deliver the right size and shape assembly for your application.

Cost Analysis Example

The graph below shows a 12 year cost comparison of an existing bed versus Grate Plate Saver®. The cost is shown in millions of dollars spent total to date.

As shown, over a 12 year period, an $11,180,000 saving would be realized by the use of the Grate Plate Savers® over the existing cooling beds. These figures do not reflect any loss of business due to scratched plate, or the potential increase due to higher quality plate coming off the Grate Plate Savers®.

As related to the graph the following example depicts typical cost savings over a period of time. Existing cooling bed a plate mill spends:

• $400,000 a year on downgrade charges due to not to spec plate
  
• $600,000 a year on repair to scratched plate
  
• $150,000 a year on grate replacement or maintenance
  
• Replace chains every 4 years at $150,000 total cost
  

Cooling bed equipped with Grate Plate Saver® mill spends:

• $2,500,000 to completely fill their bed with Grate Plate Saver®
  
• $120,000 for initial installation
  

After 8 years

• $120,000 to remove, invert & reinstall
  

Design flexibility easy adjustment and replacement of inserts

Grate Plate Saver® inserts have the ability for height adjustment. This enables individual settings of each insert to compensate for variations in grates due to distortion or wear, providing flatter rolling surfaces for flatter plates.

• Inserts are easily removed from broken or damaged grates and placed into new or used grates
  
• Additional inserts can be added to allow transfer of heavier plate
  
• Current designs handle up to a 4.00
  
• Grate Plate Saver® inserts can be exchanged for remanufactured units at a reduced cost
  

Rugged reliability proven Plesh tough

Plesh is a leading manufacturer of chain, conveyor systems, and heavy duty rollers and wheels used in the steel industry throughout the world. Our Grate Plate Saver® rollers feature renowned Plesh quality and reliability, and have proven years of field testing, with full systems in service since 1992.

• Rollers and pins are heat treated alloy steel designed to withstand abrasive wear, mechanical and thermal shock
  
• High temperature roller bearings are self-lubricating and require no maintenance
  

On-site training - only from Plesh

If you desire, Plesh Industries offers complete hands-on training at your facilities to help you properly maintain and operate the Grate Plate Saver® system. This includes training on how to properly adjust height, replace or add inserts, and other procedures to ensure the long-lasting, reliable performance of your system.

Plesh is ready to help

For 30 years, Plesh has served the needs of the steel industry for specialized material handling chain, wheels and rollers. With innovative products like the Grate Plate Saver®, Plesh has earned a reputation as a problem-solving company.Our engineers understand your process and have the expertise to assist you in obtaining the advantages of the Grate Plate Saver®.

To prepare a custom proposal for your application, here is what we need:

• System drawings consisting of all grates, aprons, roller tables, turnover arms, primary and secondary support structure
  
• Process data maximum and minimum plate thickness, annual volume and approximate volume for each size range, maximum and minimum plate sizes
  
• Any flatness and surface specifications
  

Let us demonstrate the unique solution offered by our patented Grate Plate Saver® system. Contact Plesh today.