Improving Uptime in Hot Dip Galvanizing Operations

This manufacturer needed to restore production continuity after a critical motor platform was discontinued

A U.S.-based manufacturer of galvanizing equipment relied on a legacy air motor platform that became unavailable, creating an immediate risk to production continuity and customer support. Working across engineering, product management, and manufacturing teams, a new MMP150 Series air motor solution was validated, enabling equipment redesign, improved serviceability, and a path to reduced downtime.

Key Facts

Industry: Hot dip galvanizing equipment manufacturing
Application: Pneumatically operated spin galvanizing systems
Solution: MMP150 Series air motor
Environment: High-volume, safety-sensitive, acoustically demanding operations
Revenue Impact: More than $447K in motor sales and booked business, plus accessory sales
Estimated Downtime Reduction: 30–40%

A discontinued motor platform created a significant operational and engineering challenge

This specialty manufacturer serves galvanizing facilities that depend on high equipment uptime, consistent throughput, and reliable operation in harsh industrial environments. Their flagship spinning system removes excess zinc from small metal components during the hot dip galvanizing process, making equipment reliability critical to customer operations.

In 2024, the discontinuation of a long-standing air motor platform created an immediate gap in the product offering. Alternative motors available in the market could not meet the required combination of size, torque, horsepower, and operational flexibility.

Several constraints complicated the transition:

Maintaining reliability in dirty, high-utilization environments
Minimizing downtime for end users operating continuous production lines
Supporting OSHA, ISO, and industry compliance requirements
Managing performance in high-acoustic environments
Preserving customer confidence and repeat business
Ensuring long-term parts availability and service support

Additionally, the original equipment configuration experienced balance and alignment challenges during forward/reverse operation, creating further design considerations during the transition.

A redesigned equipment package and MMP150 Series motor restored performance and supportability

In 2025, engineering teams identified the MMP150 Series air motor as a viable replacement.

To address the challenge, cross-functional teams collaborated across product management, engineering, and manufacturing operations to evaluate technical requirements, identify design alternatives, and maintain supply continuity throughout development.

The selected MMP150 Series motor provided:

Required torque and horsepower curves
Compact footprint for equipment integration
Full forward and reverse operating capability
Improved durability for demanding production environments
Long-term parts availability and service support
Enhanced maintainability for field service teams

The transition required a significant equipment redesign. The manufacturer reduced the housing size from 18 inches to 16 inches and re-engineered the overall package to accommodate the new motor configuration. These changes also resolved prior balance and alignment issues experienced during forward/reverse operation.

Following testing and validation in 2026, the redesigned solution met and exceeded performance expectations.

Safety Enhancements

The manufacturer incorporated a remote pendant control (MR-269C) to improve operator safety when working near chemical processing areas.

Key safety features included:

Remote operation capability
Controlled reversing behavior
Stall functionality during directional transitions for improved control
Braking-like action when the operator releases the throttle

The new solution improved reliability, serviceability, and customer confidence

While long-term durability monitoring remains ongoing, initial results and customer targets indicate meaningful operational improvements.

Quantitative Results

30–40% Reduction in Unplanned Downtime

Driven by improved motor reliability, stable torque performance, and readily available service parts.

20–25% Improvement in Cycle Consistency

The MMP150 Series motor reduced variability during forward/reverse operation, supporting more predictable production cycles.

Qualitative Results

Restored customer confidence following a disruptive product transition
Improved operator experience through smoother reversibility
Reduced operational strain in high-noise environments
Better engineering alignment due to redesigned housing and motor integration
Greater serviceability with accessible parts and long-term support
Production lines returned to planned operating schedules

MMP150 Series Air Motors

Delivers required horsepower, torque performance, reversibility, and long-term serviceability for demanding industrial applications.

“Our manufacturing line is back up and running, meeting production schedules, and our customers are very pleased with the redesign, performance, and delivery expectations.”

— Engineering Manager

Specialty Manufacturing Case