Final machining a pass partition after welding
Close-up of final machining gasketed surface after welding
Machined tube sheets waiting for drilling
Mike Walski, Manual Lathe Operator, final machining a pass partition
Full view of Knuth 2300 VTL
(l-r) Jimmy Ulrich, Production Manager; Annie Harris, General Manager
(l-r) Jimmy Ulrich, Production Manager; Mike Walski, Manual Lathe Operator
Perry Products Final Assembly and Hydrotest Bay, Hainesport, NJ
In an era of rapid automation and disposable goods, one New Jersey company stands as a testament to craftsmanship, longevity, and specialized engineering. Perry Products, a division of the Perry Equipment Company, has carved out a niche in the custom fabrication of shell & tube heat exchangers — critical components in countless industrial processes. With a history stretching back to 1932 and a workforce that includes multigenerational employees, the company blends decades of experience with strategic investments to meet the exacting demands of its clients.
The Art and Science of Heat Exchange
Shell & tube heat exchangers are the unsung heroes of industrial manufacturing, from pharmaceuticals to chemical processing and more. These systems transfer hot liquids or gases around tubes that contain a cooler liquid. Contact between the cool and hot liquids results in a natural heat exchange from hotter to colder. These tubes are contained within a cylindrical shell.
Shell & tube heat exchangers can feature wide temperature variations and flow rates, intense pressure, and other variables, depending on the application. Construction of these must be strong and rigid and suited for the task. Every heat exchanger is a unique project.
Perry Products, with its 17 employees, produces around 10 of these intricate vessels per month, working with materials ranging from carbon and stainless steel to high-end alloys like Hastelloy.
A Culture of Compliance and Quality
Manufacturing pressure vessels that can handle extremely high pressures — sometimes up to 1,800 PSI — demands an unwavering commitment to safety and quality. Perry Products operates in strict compliance with the American Society of Mechanical Engineers (ASME) code, a critical certification for building safe, high-quality pressure vessels.
An authorized inspector visits the facility twice a week to ensure every aspect of fabrication, from calculations to welds, is in compliance. Furthermore, the company undergoes a formal review every three years, and the code itself is updated every two years, requiring constant vigilance.
Perry Products collaborates with clients to engineer a solution that meets their exacting requirements. Using sophisticated software for thermal process calculations and Codeware Compress for mechanical design in compliance with the ASME code, they determine the precise size and specifications required. Once the design is finalized, fabrication drawings are created in SolidWorks. After customer approval, the design is released for production.
Before any vessel is shipped, it undergoes a hydro test. This test confirms that all welds and gasketed joints are sound and leak-free. The vessel is then officially registered with the National Board, solidifying its safety and quality credentials before it is installed as a fixed, vital piece of a client's industrial process.
Investing in New Machinery for Precision and Reliability
Manufacturing custom, high-pressure systems like these is not an automated process. Rather, it requires hard-working, dependable machinery.
The main forgings and parts are assembled by welding, which creates a lot of heat distortion and excess metal. These must be machined back to flat to create a proper seal when bolted together. Additionally, the components can weigh up to 2,000 lbs.
Recently, Perry Products invested in a new manual vertical lathe from KNUTH Machine Tools. The goal was to alleviate a bottleneck when machining gasket surfaces on welded components. The solution selected was the KNUTH VDM 2300 S manual vertical lathe. This machine was chosen because it closely matched the specifications and capabilities of an existing KNUTH VTL already in operation, allowing for a seamless integration into the workshop and minimized learning curve for operators.
The machine turns large flat discs or rings, which require a lot of fixturing for stability. The final machining pass, or "skim cut" on the VDM 2300 S, ensures the surface is perfectly flat for a leak-proof seal. Though the tolerances — sometimes as wide as an eighth of an inch — are "humongous" by micro-machining standards, the finish is critical. The new machine provides a smoother finish and more subtle operator control, even on a manual machine.
The VDM series offers modern, conventional solutions for machining large-diameter and heavy workpieces. Its design enables particularly easy and safe loading and unloading, making it ideal for handling demanding components. The feed drive is powered by a high-torque servo motor, and a robust hydraulic system clamps the crossbeam securely. The main drive provides high torque for heavy machining, while a side support allows precise machining of outer contours. A standard 3-axis position indicator ensures precision in all operations.
Additional features, such as optimum assembly compatibility with crane and forklift, infinitely variable feed control via servo motor, a long and sturdy vertical boom, side support with independent feed, and a reduction gear drive for maximum torque, all contribute to operational efficiency, precision, and reliability.
The decision to purchase new rather than used machinery was a strategic one.
"When you buy new equipment, you also get the benefit of working with the OEM," said Annie Harirs, General Manager, Perry Products, highlighting the importance of regular maintenance to maintain tight tolerances and ensure reliability. "We are not looking for process improvement with a machine like this, but rather dependability, reliability, and capacity."
Experience that Carries Forward
This same culture is also reflected in the company, which is supported by a deep well of institutional knowledge. The loyalty of the workforce is remarkable; the company recently celebrated a shop employee's 50th anniversary, and others have contributed decades of expertise as well — including third generation employees. This continuity provides an invaluable resource of hands-on experience that is crucial in a field where every product is custom-built. Perry Products itself is still helmed by the founding family four generations since its founding 1932.
For Perry Products, success is a carefully engineered formula: a deep respect for a multigenerational legacy, a collaborative team of skilled experts, and a forward-looking approach to technology. It is this blend that allows them to continue fabricating the highly specialized, reliable equipment that keeps modern industry running.
For more information contact:
Perry Products
25 Hainesport Mount Laurel Road
Hainesport, NJ 08036
609-267-1600
sales@perryproducts.com
www.perryproducts.com
KNUTH Machine Tools USA
590 Bond St.
Lincolnshire, IL 60069
847-415-3333
info@knuth-usa.com
www.knuth-usa.com