Marathon Pac Bulk Wire Systems

Marathon Pac Bulk Wire SystemsBulk wire systems for non and low-alloyedsteel, stainless steel, aluminum and GMAW brazing.

Marathon PacTotal GMAW efficiencyMarathon Pac is ESAB’s unique,octagonal, cardboard bulk wire drumsystem for GMAW welding wires. It hasoften been imitated, but never equalled.Foldable after use and easily shipped ona pallet, it saves dramatically on storagespace compared with common roundbulk drums. There are no metal handlesor rings; all components are recyclableand can be disposed of with standardseparated waste.06-01-11 09:07OK AristoRod non-copper-coated GMAWwires with Advanced Surface Characteristics(ASC) and Marathon Pac form the perfectcombination for applications that requiredependable long-term wire feeding overlarge distances coupled with superior arccharacteristics at high welding currents.Ideal for mechanized and robotic welding.Marathon Pac is suitable for awide range of wiregrades together witha complete familyof drum sizes. TheMarathon Pac programme coverssteel, stainlesssteel, aluminum andcopper alloys, while a choice of drumsizes offers a solution for any kind offabrication, from smallworkshops to large scale manufacturing,manual and fullyautomated, or roboticwelding.With the standard Marathon Pac,spool change downtime is cut byalmost 95% when compared to theuse of 40 lbs (18 kg) spools, providingmore “arc time” with fewer workflowinterruptions. This increases even furtherwith the Jumbo Marathon Pac with nodowntime at all for spool change withthe Endless Marathon Pac.Save on rejects and post-workingSTRENGTH THROUGH COOPERATION1040703 Aristorod Taalwissels.indd 3Save on welding downtimeMarathon Pacbenefits:Efficient handling andreduced downtimefor increased weldingproductivityProcess stability forcontinuous weldingAccurate welds for superiorweld qualityLess equipment wearfor less maintenancedowntime, lower wear partcostsUnfinished workpieces or rejectsdue to abruptspool wire endsare largely avoidedwith Marathon Pac.Moreover, eachMarathon Pac is filledusing a special reversecoiling technologyto ensure the wirecomes out straight.This results in greaterprocess stability, lessspatter, perfectlypositioned welds and,therefore, less rejectsand cleaning.A complete rangeof accessories are available for efficientinternal transport and handling and easyinstallation. No system in the world iseasier to use and saves more moneyon goods.Save on feeder wearThese unique features set Marathon Pacaside from any other bulk packagingsystem, but there is much more to gain.Marathon Pac delivers savings right alongthe entire GMAW production chain – frommanual through to robotic applicationsirrespective of local labor costs.All these savings are discussed, andquantified, in calculations based onexperiences of major global userson pages 4 and 5, concluding thatfabricators can effectively get thewelding wire for free when usingMarathon Pac.With no revolving spools, and straighterwires, there is less wear on the feedsystem. The savings on guiding tubes,feed rollers and liners should not beunderestimated.

Marathon PacA complete familyMarathon Pac is the most advancedbulk wire packaging system available tofabricators. The complete Marathon Pacfamily consists of: The Marathon Pac family.Standard Marathon PacJumbo Marathon PacMini Marathon PacEndless Marathon PacMini Marathon Pac was introduced asthe perfect solution for fabricators withmoderate usage of stainless steel wireswho wish to minimize the capital tied-upin a standard sized drum without losingthe benefits of low downtime and highproductivity.Endless Marathon Pac offers the ultimatein GMAW efficiency – a system with manyadvantages for true lean manufacturingin just-in-time production and multi-robotstations.The Marathon Pac Family – wire grades and filling content.Wire TypeStandardMarathon Pac20 x 33 in.(513 x 830 mm)JumboMarathon Pac23.5 x 37 in.(595 x 935 mm)MiniMarathon Pac20.2 x 19.7 in.(513 x 500 mm)MicroMarathon Pac23.5 x 20 in.(595 x 510 mm)EndlessMarathon Pac2 x standard orjumbo550 lbs (250 kg)1050 lbs (475 kg)2 x 550 lbs (2 x 250 kg)Ø 0.03 in.: 440 lbs(Ø 0.8 mm: 200 kg)Min Ø 0.04 in.(min Ø 1.0 mm)2 x 1050 lbs (2 x 475 kg)Non- and low-alloyed steelSolid wiresCored wiresDepending on typeDepending on typeØ 0.06 in.: 1050 lbs(Ø 1.6 mm: 475 kg)Ø 0.08 in.: 992 lbs(Ø 2.0 mm: 450 kg)SAW wiresStainless steelSolid wiresCored wires550 lbs (250 kg)1050 lbs (475 kg)Ø 0.03 in.: 440 lbs(Ø 0.8 mm: 200 kg)Min Ø 0.04 in.(min Ø 1.0 mm)Depending on typeDepending on type2 x 550 lbs (2 x 250 kg)2 x 1050 lbs (2 x 475 kg)Ø 0.06 in.: 1050 lbs(Ø 1.6 mm: 475 kg)Ø 0.08 in.: 992 lbs(Ø 2.0 mm: 450 kg)SAW wires22 x 20 in.(559 x 508 mm)AluminumSolid wires311 lbs (141 kg)Copper-basedMIG-brazing wires220 lbs (100 kg)440 lbs (200 kg)176 lbs (80 kg)55 lbs (25 kg)

Endless Marathon PacNo end to robotic productivityThe wire from a second Marathon Pac is joined tothe first using a special portable butt weldingdevice.The pear is an ESAB invention that facilitates asmooth transition when the wire crosses over fromone drum to the other. The wire passes through thepear which is placed on top of the first drum whenit is installed. When the drum is empty, the pearcrosses over while the wire conduit swings to thenew drum.Endless Marathon Pac doesexactly what it says, providingtotal efficiency with no stops forchangeover at all. Well before theMarathon Pac finishes, the wirefrom a second Marathon Pac isjoined to the first using a specialportable butt welding device. Thisprocedure takes less than a minute.The clever changeover mechanismthen automatically transfers the feedfrom the first to the second drumwhile the robot continues to weldfaultlessly.In highly automated, just-in-timeproduction, even one stop per drumis too much. For those fabricators,ESAB’s Endless Marathon Pacprovides the final step towardstotal efficiency with no stops forwire change. By repeating the wirejoining procedure, uninterruptedsupply of wire is achieved. Weldingsystems no longer have to stop forwire exchange.For multiple robot stations, EndlessMarathon Pac benefits are evengreater. No longer is it necessaryto halt an entire production cell justbecause one of the robots needs anew drum.A continuous supply of wire alsoensures against components onlybeing part-welded because spoolsor drums have emptied during thewelding sequence.

Marathon PacThe savings quantifiedTable 1: Typical cost savings for professional users - 40 lbs (18 kg) spools vs Marathon PacLow Labor CostEnvironmentHigh Labor CostEnvironmentHighly MechanizedEnvironment 12.00 62.00 300.00Operating cost USD/hr*Cost savings - USD/kg wire used*ReasonDowntime0.130.643.22Weld quality0.201.002.00Equipment wear parts0.050.100.20Total USD/kg wire* 0.50 2.00 7.00Total USD for 550 lbs (250 kg)* 120.00 545.00 1,700.00Total USD for 1050 lbs (475 kg)* 225.00 1030.00 3,220.00*USD based on average operating costs; rounded to the nearest dollar.Table 2: Downtime cost savings - 40 lbs (18 kg) spools vs. 550 lbs (250 kg) Marathon PacSpool Weight40 lbs (18 kg)550 lbs (250 kg) MPSpool changes/ton of wire55.64.0Spool change time (min)1515Total time per ton (hr)13.91.0Downtime saving (hr/ton of wire)-12.9Marathon Pac is designed to enablecustomers to get the maximum returnon capital for their automated solutions. mechanized installations. Typical cost savings forprofessional usersTable 1 gives an overview of typicalcost savings when comparingMarathon Pac with 40 lbs (18 kg)wire spools. These figures are basedon actual tests and reports fromvarious industries in both low andhigh labor cost environments, andin a fully mechanized productionenvironment.Operating costsDepreciation costs with highlyPremises and auxiliary equipmentsuch as overhead cranes andforklift trucks. Operator revenues to coveroverhead costs such assupervisors, forklift drivers,QC inspectors, management,HR, administration and sales.Being conservative, ESAB estimatesthe operating costs for a low laborcost environment to be 12.00 USD/hr and 62.00 USD/hr in a highIt is essential that full welding stationoperating costs are considered,not just the net hourly wages of thewelder. These include:labor cost environment. For highly manipulators.All indirect costs such as socialcharges, pension, sicknesspayments, holiday and overtimeallowances, productivity andperformance bonuses.mechanized manufacturing, 300.00USD/hr is typical for a weldingstation with a couple of robots andSome just-in-time suppliers in theautomotive industry calculate with 2,500.00 USD/hr.

Marathon PacThe savings quantifiedDowntime costsWelding station downtime forspool change depends on factorssuch as the set-up (accessibilityof the wire feeder, liner length,etc.), management focus onlean manufacturing, and whetheroperators are paid by finished piece.It is also influenced by the distanceto the location where spools arestored. Table 2 calculates typicalsavings on downtime for changing40 lbs (18 kg) spools versus 550 lbs(250 kg) Marathon Pac. The savingson downtime in USD/lb wire for thethree operating levels are shownin the 3rd row of Table 1 and anestimated 15 min. change for bothspool or Marathon Pac.Weld qualityStable feeding and straight wiredelivery from Marathon Pac resultsin well positioned joints with goodpenetration and appearance, lessspatter and less post weld repair.Quantifiable results are availablefrom a well-known mass productionautomotive components company.Savings due to the reduction ofwelding defects, rework, grinding,scrapped materials, etc., amountedto five times the cost savings ondowntime only for the 62.00 USD/hr operating cost group in Table 1.This means that their recordedbenefits exceed 1.15 USD/lbof wire, purely due to improvedweld quality. In Table 1, we stayconservative with 0.60 USD/lb forthe high cost environment, a levelconfirmed by other studies in thisfield and 1.15 USD/lb for the highlymechanized environment. For the lowcost environment we have reducedthe quality savings to only 20% ofthe high cost group, mainly becauserework costs are lower.Equipment wear partsThe absence of a turning weight, aswith 40 lbs (18 kg) spools, leads toreduced wear in the feed system,eg, liners and feed rolls.conditions, savings will be at least thesame, or exceed, the cost price ofthe wire. Marathon Pac is therefore,more cost-effective than spools inany environment and could effectivelybe free of charge!ESAB has studied the wear andspare parts costs for industrialusers. Typical consumption isaround 2 tons of wire/year perwelding machine. Typical wearparts cost 250.00 - 500.00USD/yr per welding machine(labor costs excluded).In Table 1 we have again beenconservative, taking 250.00 USD/yras a representative figure for spareparts. For the low cost environmentthe assumption is that spare andwear parts costs per pound of wireis never less than 50% of the above,eg, 0.03 USD/lb of wire. For the highlabor cost environment, the savingamounts to 0.05 USD/lb of wire.In the highly mechanizedenvironment, as downtime is socostly, manufacturers should allowa higher safety margin in terms ofpreventive maintenance. It is realisticto double the cost in comparison withthe high labor cost environment.Marathon Pac pays back.Changing to Marathon Pac alwayspays back, regardless of the costenvironment. The total savings inthe low operating cost column ofTable 1 are not necessarily “typical”,but minimum. From the higher costcolumns, anyone buying GMAW wirewill understand that under “typical”Straight wire delivery results in wellpositioned welds and fewer rejects.Straight wire delivery