Since its inception in 1982, Atlas Roofing has carved its path to becoming a front-runner in the roofing and building envelope manufacturing industry. With a vast footprint spanning 33 locations across the United States, Atlas Roofing's story is one of consistent growth and strategic expansion. The case at hand revolves around their Atlanta-area facility, which was grappling with a pressing need to augment its capacity for asphalt shingle production without disrupting its existing operations.
The challenge was crystal clear: boost production capacity while ensuring the smooth sailing of ongoing manufacturing processes. Given the delicate balancing act required, Atlas Roofing sought incremental improvements to their systems. With a longstanding partnership with Pye-Barker Engineered Solutions—a name synonymous with engineering solutions since 1936—Atlas Roofing had the backing they needed to dive deep into the problem.
Led by the collaborative efforts of Pye-Barker Engineered Solutions' Paul Grillet and his counterpart at Atlas, the teams embarked on a mission to enhance production without significant system upheavals. The focal point was the facility's sealant pump—a critical component that was failing to keep pace with the heightened demand for asphalt shingles. This pump, vital for applying the modified asphalt that binds the shingles, became the linchpin in the quest for increased productivity.
The existing Viking K224A sealant pump, coupled with a Browning 15:1 gear reducer and a 1-horsepower motor, was delivering a flow rate of 11.5 gallons per minute (GPM). With demand on the rise, Atlas Roofing needed more. The solution? Pye-Barker Engineered Solutions' recommendation to replace the old pump with a new Viking KK224A model. This new pump was dimensionally identical, yet boasted a 25% higher capacity. By also swapping the gear reducer to a 10:1 ratio, the teams doubled the flow rate to 23.8 GPM, remarkably without necessitating any changes to the piping or base.
The transition to the new system was seamlessly integrated into a scheduled upgrade, ensuring zero disruption to production. This strategic move not only doubled the capacity but maintained the existing mechanical footprint—an ingenious way to balance the need for growth with the practicalities of ongoing operations.
Atlas Roofing's success story is a testament to Pye-Barker Engineered Solutions' enduring commitment to providing expert engineering solutions and unparalleled customer service. The partnership between Atlas and Pye-Barker Engineered Solutions, fortified by collaborations with top-tier manufacturers like Viking Pumps, exemplifies how targeted improvements can lead to substantial gains.
Atlas Roofing's case is an exemplary model of how businesses can expand capacity and improve output through intelligent, incremental changes, backed by the right partnerships and expertise.
Ready to optimize your production without major overhauls? Contact Pye-Barker Engineered Solutions today and let us engineer a customized solution that delivers immediate results and a tangible return on investment for your business. Call us today at 404-363-6000 to discuss your needs with our team, or visit us at https://pyebarker.com/contact-us/ to leave us a message.
