Above: CleanCut’s nozzle design pressurizes the flow of gas. Once the pressure is released, it provides a narrow, stable plasma arc.
Patented CleanCut technology from American Torch Tip reduces consumable consumption
April 2019 - Every minute of downtime costs companies money. “Our goal with consumables is to keep that machine running for a longer period throughout the day so people are making more money with their investment,” says Justin Bancs, inside sales representative for American Torch Tip, Bradenton, Florida. “Hands down, the electrode and nozzle are the most commonly replaced parts in a stack-up, so our goal is to make it so customers change those less. With that comes the inherent advantage of less downtime from the torch, less wasted labor and the machine stays running longer.”
American Torch Tip’s CleanCut technology focuses on these high-volume components and includes an electrode and a nozzle that are plug-and-play for most systems.
CleanCut electrodes run cooler due to their higher thermal conductivity versus conventional plasma electrode designs. “As far as longevity goes, getting a more complete burn on the hafnium is really what makes a consumable last longer,” says Bancs. The electrode is paired with the CleanCut nozzle that Bancs calls a “completely new innovation.”
The nozzle has a patented high-velocity design that reduces turbulence, stabilizes and accelerates the plasma arc column. It pressurizes the flow of gas and, once the pressure is released, it provides a narrow, stable plasma arc. “Typically, standard nozzles have hard angles inside,” he says. “When air is flowing through, every time it makes a hard transition, it causes turbulence. A lot of other companies will have blowback or vent tubes to release pressure out of the back side of the torch. Our torch gives users more complete use of the gas.”
Tried and tested
CleanCut was developed in response to a common customer request for longer lasting consumables. Bancs says, “We told our engineering team what customers were saying they wanted and asked them, ‘What can we do to make this happen?’”
American Torch Tip is partnering with potential customers to ensure they understand the benefits and potential if they switch. “We have a testing process,” Bancs says. “Companies document the life of their standard consumables, and then we put our CleanCut on and have them track the life of those. So far, the ones I’ve worked on have all seen in the range of 28 to 30 percent savings, and we amortize that out over a year.”
Those savings are “strictly based” on longer life, Bancs says, money that customers keep in their pockets because they’re no longer eating up consumables. It doesn’t take into account the time it takes to change consumables or longer arc-on times because those factors are “more subjective, and we are going off what we can actually prove on paper.” Other benefits may include less dross and slag, less unintended bevel and overall cleaner cuts.
In addition, the comparison and switchover are seamless. “American Torch Tip designed and tested CleanCut to use the OEM-set feeds and speeds,” Bancs says. “We’re trying to keep as many controls as possible so customers get a true comparison. They don’t have to change anything.
“There’s very little buy-in on their part,” he continues. “They just have to commit the time to document the consumables. We’re trying to forge a partnership with our customers and move forward together with them, rather than just pushing parts. We want to improve what they have and offer a savings on top of that.”
American Torch Tip
Bradenton, Florida
800/342-8477
