Production Starts with CNC
Puck Enterprises began as a manure application company, but today it encompasses the process from start to finish. That includes our in-house manufacturing to create the very equipment our crews use to apply the manure. Since building the first hose cart, Puck has spent more than a decade making their production line more efficient. Each piece of equipment is crafted and assembled at Puck in Manning, Iowa. When a manufacturing order comes through the Puck system, the parts needed to make the equipment will enter the work queue.
Cutting Pieces
Most pieces will go through the CNC Department first, which relies on computer numerical control for operating machining tools. A CNC technician will “nest” any parts that need to be cut with a laser by utilizing a program on his computer. By nesting the parts, the tech is placing the cutouts of parts that need to be cut onto the software’s mockup of sheet metal. It is arranged in a way to minimize metal waste and maximize parts cut. Once the cutouts have been nested, the computer can send that program to the laser cutting machine, where sheet metal has been loaded in.
The metal plate used for making a TTR 20 motor mount is A36 ½ inch plate steel that weighs over 1,000 pounds per sheet. The laser cutting machine allows CNC techs to load metal sheets on one side of the machine while the laser is cutting on the other side. The machine pierces holes across the metal sheet before later cutting the parts out from the programmed nesting from earlier. Once the laser cutting is complete, the machine will offload the metal sheet to allow CNC techs to take the newly cut parts. The frame of the metal sheet that is left is sent to local high schools for students of welding programs to use in class.
Shaping Pieces
Once cut, parts are brought down the production line to the press brake to be formed into its proper shape. The hydraulic press brake has the pressure of more than 260 tons to bend the metal pieces. With each fold made to the ½ inch metal sheet, CNC techs measure the angles of each bend for quality esurance. When the motor mount parts have been formed to the proper shape, the pieces fit together to form a sort of box for the hydraulic pull motors that will operate the hose cart reel. This is brought to the Fabrication Department for welding.
A fabrication tech will be given the blueprint of the specific parts for each task to see how it should be welded. Once they have put the pieces together and the angles are all found to be correct, the fab tech will tack the motor mount together in a few spots to avoid movement while welding. From there, they can check with the blueprint to see which features of the piece should be fully welded for optimal durability.
Painting & Installation
After welding, the part gets cleaned up and brought down the production line to the Painting Department. Parts are hung on a rack and move from one room to the next through the process, beginning with a wash down. From there, it is coated in a primer and baked at 400°F until the temperature of the metal reaches around 300°F. The priming step may be repeated until the desired thickness of primer is reached. The additional layers of primer help minimize the chances of paint cracking on the metal. After the primer has baked and the rack has cooled, it is given a powder coating of the final color before being baked one more time.
Once the powder coating process is complete and the motor mount part has cooled, it is moved to the Assembly Department. Assembly techs use hoist cranes to lift the motor mount and hold it in place while being drilled to the side rails of the TTR 20. The two-speed hydraulic pull motors are installed within the motor mount on each side of the hose cart and are used to turn the reel.
You can watch the full video of a TTR 20 motor mount from start to finish on our Facebook page. To learn more about Puck’s manufacturing process and the people who make our products, check out our blog. Read stories from long-time employees and learn about the different jobs at Puck Enterprises.