OVEN REBUILD & RETROFIT VS NEW OVEN REPLACEMENT

Oven end-users often struggle with equipment that no longer meets their current production and/or process needs. You might even be experiencing this yourself…

The decision to tear-out your existing equipment to replace it with new equipment versus repairing, retrofitting, or rebuilding what is already in place can have cost and down-time implications that severely impact your bottom line.

So, we wanted to share a case study with you to show you the benefits of knowing the options available to you…

The BackGround

  • Manufacturer of aerospace vehicles
  • The oven needed to hold full fuselage or wing sections
  • Composite curing of vacuum-bagged sections and components
  • The required process time varied based on part size with a max. temp. of 392°F (200°C)

This is a manufacturer in the aerospace industry needing an oven large enough to hold full wings or a sections of wings.

This oven will be used for composite curing of vacuum-bagged sections and components and must have the ability to handle various process times at a specified maximum temp.

Observed Initial Condition

  • Oven purchased used in 2013
  • Oven parameters:
    • Inside dimensions 27’W x 10’H x 40’D
    • 4” thick walls
    • 12 indirect-fired burners: 400,000 Btu/Hr each, 1/3 of which were ruptured
    • 12 recirculation fans: 20,000 CFM each, 1/2 of which were spinning backward
    • Supply duct – both sides with slots
    • Return opening – wide open return overexposed heating tubes
    • Temperature uniformity was recorded to be ±65°F (36°C)
  • Only the middle 15’ could be used

Although this oven was fairly new, there were 12 ruptured burners, the circulation fans needed to be reworked, airflow needed to be improved and the control system wasn’t sufficient.

Oven Modifications

Instead of scrapping the entire oven, here’s what he did instead after assessing our options…

  • Replaced all 12 burner tubes
  • Added new VFD for each recirculation fan
  • Added control system improvements
  • Added return ductwork with adjustable louvers under the burner tubes

As a result, we were able to revise the temperature uniformity measured ±3°F.

NOW, YOU MIGHT BE WONDERING HOW THIS COMPARES TO A NEW OVEN REPLACEMENT.

Here’s what that would look like…

New Oven Cost and Timing

Oven Demo:

Replacement Oven:

Oven Install:

$11,000

$730,000

$68,000

Total Replacement Cost: $809,000

Oven Delivery: 20 weeks

Oven Install: 6 weeks 

Total Oven Delivery Time: 26 weeks

Total Down Time: 8 weeks 

Rebuilt OVen Cost and Timing

Materials:

Field Labor:

$64,000

$67,000

Total Rebuild Cost: $131,700

Total Oven Delivery Time: 8 weeks

Total Down Time: 4 weeks 

The Results

Cost Savings: $677,000

Delivery Time Saved: 18 weeks

Down Time Saved: 4 weeks

As you can see, we’re not in the market to just sell new ovens.

If it’s not in your best interest, it’s not in ours and this is just one example.

This is why we feel so strongly about helping you understand your options when it comes to finding the perfect solution for your industrial oven needs. It’s also why we’re known as the oven industry experts.

No matter the condition of your current oven or your set of business circumstances, we look forward to serving you the best way possible.

Oven Questions? Contact PQ Ovens

Contact our experts about industrial oven repair and oven maintenance services or if you need oven replacement parts. We also do industrial oven installations!

We look forward to hearing from you, and building one of the best industrial ovens in the world for your business.

 

Just email us or send us a message (at right). Please allow for up to 48 business hours to receive a reply. You can also call our industrial oven repair and parts department any time at