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Application magnetic pulsator Kendrion

Udderly Genius Designs

Electromagnetic Pulsator - Milking

Electromagnetic Pulsator - Case Study Dairy

A long-time industry leader in the cow milking field had a specific problem. For their issue, the company reached out to Kendrion Mishawaka. In the 1960’s, when their current milking equipment hit the market, they were thought of as innovators. However, the competition had plans to catch up. They took advantage of expired patents and, as a result, captured a sizeable chunk of the customer’s service part business from them. Not only was the client’s equipment over five decades old, competitors were causing a dent in their bottom line. A quick search of the cow milking industry literature showed numerous knock-offs of the equipment. Even worse, they all claimed to be compatible and were being offered at a lower price. The customer and Kendrion Mishawaka agreed to go back to the drawing board and make a new, quality part to recapture their innovator status in the industry and bring back income from the service parts business.

Kendrion Mishawaka had seen and dealt with problems like this over the past several years. As with most coils and valves designed in previous generations, the design and cost drivers have changed considerably. The big factor is the cost of copper. What used to cost $1 in copper back in the 1960’s cost ten times that now. When talking about a large part order for a specific product, that’s a ton of money either spent or saved. Another component is that factory labor is more expensive and different materials used in valve fabrication are now available.

In doing the finite element analysis of the existing design for the customer in the cow milking industry, Kendrion Mishawaka discovered several inefficiencies that contributed to a lackluster part. Also, the valve assembly consisted of a thermoset encapsulated body with many additional pieces including seals, fasteners and external ports. With this, there was an opportunity to improve the design and lowering the overall production cost was highly viable. When Kendrion Mishawaka puts its mind to a project, solutions come in a hurry. In this case, initial concepts were developed and put in front of the customer within just two weeks.

An encapsulated valve coil was developed that incorporated many features that had been separate parts. This reduced the part count. Also reduced was copper content and cost because of the optimized design. The existing thermoset plastic body was replaced with a more flexible and manufacturing friendly thermoplastic. The topper was renewing the patent viability through a novel sealing arrangement. This also ensured a revenue stream from customer service parts business and recapturing those lost profits from competitors.

There were a variety of positive results. For starters, the customer released its first all new system in over 30 years. In addition to a lower cost and reduced part count and complexity, it lowered the down-time in their milking parlors. Lastly, they regained their strong presence in the service parts business. Kendrion Mishawaka delivered on its promises to the customer and created a long-lasting, efficient component for the cow milking industry.

We work on projects like these every day. A customer will approach us and have a certain problem that needs to be addressed. Our expert team of engineers will design an efficient product to meet your specifications. See our entire lineup of products and services to learn more about Kendrion and our capabilities. If you have an idea for a project or need help with a more cost-friendly solution, reach out to us directly and we’ll get to work on your question or issue.

We work on projects like these every day. A customer will approach us and have a certain problem that needs to be addressed. Our expert team of engineers will design an efficient product to meet your specifications. See our entire lineup of products and services to learn more about Kendrion and our capabilities. If you have an idea for a project or need help with a more cost-friendly solution, reach out to us directly and we’ll get to work on your question or issue.