Roman Electric Co. Quality Service since 1929

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Milwaukee (414) 771-5400
Racine/Kenosha (262) 886-3742

Industrial  Remodeling

 

Why Choose Roman   Electric Co.?

Whether constructing additions, renovating plants, automating equipment or upgrading power systems, remodeling industrial facilities requires specialized skills. That's why construction managers, general contractors, and owners and managers of industrial firms have relied on Roman Electric since 1929 for skilled design and construction when remodeling.

 

Roman electrical engineers and designers can provide customized electrical power, production and lighting systems to fit your need and desires. Then Roman's highly trained industrial electricians install the new or renovated systems.

 

Electrical remodeling by Roman includes the most effective distribution of power, maximum safety, use of highly efficient materials and tooling, compliance with all local codes, and complete customer satisfaction.

 


Experience and Capability:

 

Toshiba Rebuilds Generator Rotors in Their New Clean Rooms

 

Recycler Develops Unique Plastic Recovery System

 

Roman Industrial Power Conversion Technology Keeps Briggs & Stratton Plating Line Running

 

Industrial Press Rebuilt Like New at Fraction of Cost

 

Bombardier Renovates 600,000 Sq. Ft. Plant

 

Magnetek Rapidly Consolidates Production Lines to Improve Efficiency

 

DIC Imaging Opens Completely Rebuilt Manufacturing Plant

 

New Automated System Improves Plating Operation

 

Industrial Machinery — Programmable Logic Controllers (PLCs), Soft PLCs, Drives

 

 

 


Toshiba Rebuilds Generator Rotors in Their New Clean Rooms

 

Some of the huge, turn-of-the-Twentieth Century Allis Chalmers buildings live on. One serves Toshiba. In a small corner of its enormous facility at 66th and Washington, Toshiba has constructed four clean rooms to rebuild rotors for its power generating customers.

 

Pinnacle Construction was the general contractor on the job. Roman Electric Company Inc. handled the electrical installation.

 

Roman project manager on the job, VP Gabe Rose, said they reconfigured an existing space into four permanent clean rooms. That included a new service, new fluorescent lighting, over 200 receptacles, 400 amps for the clean rooms, and different power configurations so they can plug into 480 or 120/208 volt three phase services to easily check windings on varied voltages. Jeff Jacobi was Roman job leader on the project.

 

Toshiba Project Manager Tim Kieffer said the clean rooms are environmentally controlled to keep the rotor windings clean and dry for extensive electrical testing, and to prevent insulation from absorbing moisture.

 

“Roman did a good job,” Kieffer said. “We had them here through the whole clean room project. We also have a Roman electrician here most of the time to disconnect and remove old Allis Chalmers electrical systems, and reroute and relocate underground crane supply DC lines.

 

“We have a good working relationship with Roman, they had a flexible crew and worked well to fit our schedule. During clean room construction lulls they worked on other things in the plant. We are very satisfied with the outcome”

 

Kieffer said the lighting in the clean rooms is very unusual. The fixtures are set at angles because overhead lighting would cast shadows into the deep slots in the rotors where the coils are wound. New coils and insulation must be clean, orderly and properly installed.

 

Paul Scott, Pinnacle Vice President of Business Development, said, “I’ve done a lot of work with Roman over the years. They’re very thorough. And they know that facility better than anyone. So if anything goes wrong, they have the answer. Plus they’ve got some great guys. Their electrician Joe is almost there full time. He’s a smart guy and knows what he’s doing.”

 

He said Roman is a very experienced contractor when it comes to working in older facilities like this with DC power, high voltage and non-typical machinery.

 

Scott said, “It’s a really bizarre scenario where you have existing systems that you can’t replace and can’t modify so you have to work around them. Not many guys can do it but Roman is very familiar with doing that stuff. Roman’s good. They’ve got some amazing talent.”

 

Toshiba engineers use Six Sigma process improvement strategies to maximize efficiency Scott said. If something breaks down or isn’t working properly they have redundancies in all systems so they can quickly switch to alternate plan A, B, C, D or E as needed. If their customer says we need this back in one month, Toshiba delivers in one month.

 

Scott said Roman built and customized the electrical power to satisfy these diverse systems. Electrical stations include electrical panels, transformers, Hubbell switches, 110, 220 and 480 volt outlets, single phase and three phase, varied plug and play components, all mounted on huge H frame metal racks positioned inside and outside clean rooms to accommodate any Toshiba scenario.

 

 

 


Recycler Develops Unique Plastic Recovery System

 

In an entrepreneurial process of major investment, and extensive research and development, Recycling Solutions has created what one of the partners Mark Oliver calls “a new plastic recovery line that is the only one of its kind in the world.”

 

They built the system in a 48,000 sq. ft. building at 2929 S. Chase Ave., the former Pelton Casteel foundry. Roman Electric installed the power needed for the complex system.

 

Oliver and his three partners began by recycling metals as Action Recyclers in 2005. Later they added cardboard and plastics. Then they saw opportunity when they watched the process used by cardboard recycling mills. Bales of cardboard are dropped into a 30’ wide, 20’ deep vat of water to break down the cardboard and recover the fiber.

 

But about 12% of the material is waste that was in, or part of, the cardboard boxes, which the processor has to pay to dispose of in a landfill. Included are wire ties, staples, plastic wrap, aluminum cans, glass bottles, metal parts, etc. The processors capture some of the waste by suspending a 2” rope in the vat. It builds up to about 24” in diameter by 72’ long and is called a “ragger tail”.

 

Planning to recycle the steel in the ragger tails, Recycling Solutions contracted to haul them from the processors. To find a shredding machine for the tails, they eventually found a German manufacturer willing to customize two machines to fit their needs.

 

That was the first step in building the recovery line that grew to include the shredders, magnets, fans, conveyors, shakers, a unique optical sorter, air jets, other conveyor lines, dry and wet granulators, wash systems, dryers, heaters, an extruder, cutting blades, water coolers, a vacuum system and storage silos.

 

Sadly, the company could find no American manufacturers offering, or willing to customize, the equipment they needed. Major machinery in the system is from Germany, Austria and Italy.

 

To power the array of machinery Roman Electric installed a 3000 amp, 277/480 volt 3-phase main service and a vast network of different size conduit, some color coded to indicate 480 volt power, control power and safety interlocks. Roman also installed process control timers on several machines to facilitate system activities.

 

Mark Oliver said, “We had another electrician here but their crew just wasn’t big enough to do the job and get it done in time. One surprise for me was Roman is a union shop so they have scheduled meetings, breaks, lunches and they’re gone at 3:00. But the next morning at 6:00 they’re back and on the same schedule.

 

“When they’re working, that’s all they do is work. It was really nice to see how they produced. Roman did an excellent job. Their foreman Mike Blankenmeyer ran a real tight ship and he’d have 8 to 12 guys here at any given time every day for two months. They all had their tasks and they’d get them done. They were just phenomenal to work with.” Barry Dickinson, Roman Commercial/Industrial Service Manager, supervised the job.

 

Oliver said they now recycle ferrous and nonferrous metal, produce plastic pellets reused by plastics manufacturers, and process plastic and fiber into “fluff” which is used as a fuel source producing almost the same BTUs as coal at 1/10th the cost. He said his goal is to have Roman back later for power adjustments because they designed the plant to add a second optical sorter, wash line and extruder allowing them to double their volume.

 

“We’re pretty excited about what we’re doing,” Oliver said. “We’ll process and recycle 3.600 tons of product per month that would have gone into a landfill. And 35% of that is plastic residual that doesn’t biodegrade. Our phase III plan is to incinerate the fluff on site to generate the energy we need to become 100% sustainable.”

 


Roman Industrial Power Conversion Technology Keeps Briggs & Stratton Plating Line Running


Chuck   Dingel, Briggs & Stratton team facilitator, inspects a new  rectifier  which Roman will install with the other rectifiers powering  the plating  line.Roman industrial electricians skilled in power conversion technology help keep Briggs & Stratton's plating line running. Briggs powers the plating operation with 22 rectifiers, electrical devices that convert 460 volt alternating current to the 0 to 9 volt direct current powering the plating equipment. The Roman electricians are trained and certified in rectifier service and maintenance.


After     applying a temporary power load, Roman foreman Jay Haldeman bench   tests  a   nearly 25-year-old rectifier used in the plating operation.   He  tests   components to make sure the SCRs and firing boards still   operate  as   designed. He also uses his oscilloscope to verify the   quality of  power   wave forms."Roman takes care of all our rectifier periodic maintenance," said Chuck Dingel, Briggs & Stratton team facilitator. "When we replace a rectifier they disconnect the old unit and power up the new one. They take care of all the busbar work, and everything electrical related to the rectifiers. We hardchrome over aluminum which is critical work on the pistons we use in our engines. If a rectifier goes bad it can impair the quality of the plating.


"We weren't happy with the service we were getting from the previous electrical contractor so we brought in Roman. They do an excellent job. Their electricians are faster so my downtime is very minimal. Plus they're less expensive."


Because the plating line generally runs 24/7, Roman services the rectifiers during temporary shut downs or off line when needed.

 

 

 


 

Industrial Press Rebuilt Like New at Fraction of Cost


A Roman automation specialist tests the operation of the rebuilt   500 ton plastics compression press.An older 500 ton industrial press was quickly and completely rebuilt to give Master Mold a compression molding press at about 30% the cost of a new machine. Industrial Rebuilding & Machining handled the mechanical reconstruction and hired Roman Electric to totally rebuild the press's electrical and electronic systems.

 

Image 1: The programmer can control all press-to-mold operations   from the touch screen. | Image 2: Roman completely rebuilt the press   controls with state-of-the-art Programmable Logic Controllers, Human   Machine Interface and Softstart.Master Mold, headquartered in Mauston, WI, produces reinforced fiberglas products from Sheet Molding Compound on its 23 compression molding presses for a variety of OEMs.

 

Master Mold president Jerry Snider said they decided to rebuild because the used press they found was stored more than operated, and a comparable new press would have cost in excess of $500,000 and taken eight - nine months to build. The rebuilt machine was put into production in less than three months.

 

Roman specialists automated and customized the press to fit Master Mold's needs, and retrofit electrical systems to meet OEM safety specs and codes. State-of-the-art automation included Softstart for the 125 HP motor which increases ease of use and motor longevity, Programmable Logic Controllers for maximum control and flexibility, and Human Machine Interface.

 

HMI is a data collection and analysis system giving the operator complete control of all press-to-mold velocity, dimensioning and pressure. The new computer touch screen enables the programmer to set up and input "recipes" for specific molding applications, and then store them in memory for fast, accurate, simple reuse.

 

Rock Breitzman, machinist superintendent for Industrial Rebuilding, said, " Roman's crew did a wonderful job. They built a brand new control from scratch. We like working with them."

 

 

 

 

Bombardier Renovates 600,000 Sq. Ft. Plant

Bombardier Recreational Products, a $21.6 billion global giant,   relocated its world headquarters for outboard engines to this 600,000   sq. ft. plant in Sturtevant. Bombardier completely renovated the plant   which was built by Golden Books for printing in 1997.Bombardier Recreational Products, the $21.6 billion manufacturer of products ranging from Lear jets to Amtrak trains to Ski-doo snowmobiles, has bought and renovated the 600,000 sq. ft. former Golden Books plant in Sturtevant. Bombardier bought Evinrude Johnson outboard engines two years ago and has now relocated production from Waukegan, IL to the huge Sturtevant plant which serves as Bombardier world headquarters for outboard engines.

 

Roman Electric's Racine/Kenosha office helped construction manager Axor Construction of Montreal and general contractor Berghammer Corporation remodel the plant in record time. For Roman it was the second time around since they designed and installed the original high-capacity 10.4 megawatt electrical system when the Golden Books plant was built in 1997. Roman had a crew of up to 38 electricians on the $2 million plus renovation.

 

Renovating the Bombardier facility was the second time around for  Roman Electric, which designed and built the huge, original electrical  system for Golden Books. Here, outboard engines near completion on  Bombardier's powerhead assembly line.Roman disconnected existing printing equipment, reconfigured the electrical system, powered an array of CNC equipment, and installed assembly lines. Roman had separate contracts with Logic Systems to install wiring for 7,000 ft. of overhead conveyors and a spray paint line.

 

The challenging, constantly changing job for Roman included new and existing equipment, repairs, debugging and ongoing service work. Because Axor required fast turnaround for time & material billing, Phil Rose helped set up a T&M billing system the Roman foremen used for daily pricing.

 

Roman Electric substantially rerouted and upgraded electric power      to accommodate Bombardier's manufacturing equipment. The automated   line    of CNC equipment at right produces cylinder heads (left) for   outboard    engines.Michel Bouchard, Axor on-site director, was pleased with Roman's work. "Roman knew everything in the plant because they built the existing electrical system so it was very easy for us to modify and manage power and wiring. Roman's crew, engineer Phil Rose and project manager Rick Kugel were all very good. We started work August 1st and by September 15th had the first line ready to start producing outboard motors. That kind of speed was a big miracle."

 

Bombardier is now producing about 200 outboard engines per day. Also key to Roman's success were division vice president Bernie Cleppe and foremen Mel Brady, Mike Czerwinski, Jerry Pipol, Andrew Hogard and John Sommers.

 

 

 

 

Magnetek Rapidly Consolidates Production Lines to Improve Efficiency


Image  1: To improve plant efficiencies, Magnetek consolidated its  Electromotive Systems and Elevator Products divisions in one of its  Menomonee Falls manufacturing plants. Roman Electric installed a much  more powerful 2000 amp service and distribution system. | Image 2: Roman  installed a new 2000 amp customized electrical system with specialized  multi-voltage testing equipment for Magnetek's renovated R&D plant.Magnetek, an international leader in the manufacture of power electronics and industrial controls, consolidated two operations to improve efficiencies. It moved its Elevator Products division from New Berlin to share two buildings totaling 85,000 sq. ft. in Menomonee Falls with its Electromotive Systems division.


Magnetek requirements included fast relocation to limit manufacturing down time and a significant upgrade in electrical capacity to power production and two R&D labs totaling 20,000 sq. ft.


Jim Parks, project manager for renovation general contractor Berghammer Corp. said, "We got Roman involved at the beginning because the project was so intensely electrical. Given the size of the space I would never have guessed that there would be $350,000 worth of electrical work needed, which constituted 2/3 of the budget.


"So it was valuable for us to have a capable design/build partner like Roman. They've got talented people and are very good at uncovering the needs of the client - they're very proactive."


Roman project manager Dennis Strenk, foreman Dave Emmery and a crew of eight electricians installed new 2000 amp services in both buildings to substantially upgrade the power systems.


Roman helped custom design the new lab and testing area to provide several different power voltages to 12 test and development benches. They installed two large, specially designed 400 KVA multi-tap transformers for testing drives with a variety of voltages.


Roman's crew also helped shut down, rewire and upgrade production equipment moved to the renovated plant so quickly that only two days of production were lost. Tim Schallhorn, process improvement manager for Magnetek's Industrial Controls Group, said, "Dennis and Dave were very knowledegable, and helped us understand our needs and develop a plan. We couldn't have done it in time without them. Roman did a great job."

 

 

 

DIC Imaging Opens Completely Rebuilt Manufacturing Plant


DIC  Imaging gutted an older 30,000 sq. ft. plant and rebuilt it into an  impressive new facility for manufacturing toner products previously  exported from Japan.A 30,000 sq. ft. plant built in the '70s has been gutted and completely rebuilt by DIC Imaging Products USA, a new subsidiary of Dainippon Ink and Chemicals (DIC, Japan). The plant at 7300 S. 10th Street in Oak Creek will be staffed by Reichhold Chemicals, another DIC subsidiary.

 

Roman  electrician Dan Hafemeister installs wiring for a classifier, which  screens liquid toner to the proper size.DIC Imaging manufactures specialty toner products for high-speed computer printers and will eventually produce the entire line of DIC toner products. The company will manufacture the same products that previously had been exported from Japan, significantly reducing delivery times.

 

Rapid Construction

Math Stark & Sons performed the building reconstruction. Huffman Engineering of Lincoln, Nebraska served as design consultants. The facility has new structural steel, roof, HVAC components and a new electrical system installed by Roman Electric.

 

Al Naser, president of DIC Imaging, said, "We had a very aggressive schedule and Roman's work was a major part of our meeting that accelerated timetable. I'm very pleased. They did a terrific job."

 

 

 

 

 

New Automated System Improves Plating Operation


At  Milwaukee Plating, an array of parts moves through a 75 ft. series of  repeated cleaning, acid pickling, rinsing and plating baths. Roman  installed power for the new plating line and interconnected hundreds of  power and control elements with the plating machine PLCs.A new, custom-built automated nickel chrome plating system installed by Milwaukee Plating has allowed it to remain competitive with low-labor overseas competition. Milwaukee Plating provides copper, nickel, chrome, zinc, silver and tin electroplating of parts for over 250 regional firms.


The Fanta electroplating machine and 75 ft. long custom plating line cost $900,000 to buy and install. "Roman Electric did a beautiful job powering the line for us," said Milwaukee Plating president Al Mattacotti. "Their work was well-engineered to properly make all the electrical connections in a long, detailed network."


Roman installed a 600 amp 480 volt service to power the new line. Then Roman industrial specialist Dave Hedin interconnected the complex system of rectifiers, PLCs, electrical and hydraulic plate and quench controls, limit switches, safety features and waste treatment controls. Roman also installed new metal halide lighting along the plating line to improve parts inspection.


Mattacotti said the new plating line has substantially improved productivity, consistency and quality.

 

 

 

Industrial Machinery
Programmable Logic Controllers (PLCs), Soft PLCs, Drives

Electrical/electronic expertise on all stationary industrial machinery, small or large, indoors or outdoors, with or without PLC's, motors, relays, starters, switches, power supplies, etc.

 

Banner 01Drives

Repair, replacement and startup of drives from 1/2 HP to 4000 HP.... Direct Torque Control, Pulse Width Modulation, Soft Start..... Speed control or constant torque for pumps, fans, centrifugal machines, mixers, conveyors, open or closed loop..... All drives including ABB, AB, Sqare D-Telemecanique, Siemens, etc.

 

PLCs

Proper PLC selection depends on your application, capability needed, space and budget. A PLC is basically a packaged control solution.

Capabilities can include: Control, evaluation and adjustment of applications in real time.... Precision automation..... Real time data and documentation for pieces produced, material used, temperatures, liquid flowage, quality control, scheduling, shipping, maintenance..... Integration of factory floor data with management systems..... Audible voice messages..... Communication interface with other equipment, computers and PLCs..... Ease of data transfer.

 

Soft PLCs

Compatible with Windows or Windows NT..... PC Programmability..... Spreadsheet Capability..... Statistical Process Control.

 

Many Features

PLCs and Soft PLCs are available in hundreds of types and sizes with thousands of feature choices: Broad range of local and remote I/O styles and options..... Compatibility with software platforms..... Compatibility with software platforms..... Display monitors..... Alarm screens..... Counters..... Touch screens..... Keypads.... Serial connections..... Event interrupts..... Motion controls..... Diagnostics..... Hardware & software securtity..... Varied AC and DC power..... Electrical circuitry.

 


 

  1. A Crew of Highly Skilled Electricians
  2. Continuous Training with an Emphasis on Safety
  3. A fleet of 50 Service and Bucket Trucks
  4. A Staff of Professional Engineers, Designers and Technicians
  5. Full Service Design/Build Capability
  6. Wisconsin's Energy Efficiency and Renewable Energy Experts
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Milwaukee
640 S. 70th Street
Milwaukee, WI 53214
(414) 771-5400 · Fax: (414) 471-8693

Racine/Kenosha
2900 Wisconsin Street
Sturtevant, WI 53177
Phone: (262) 886-3742 · Fax: (262) 886-3082