OLDCASTLE BUILDING ENVELOPE

DALLAS, TEXAS HEADQUARTERS

Oldcastle Building Envelope is the leading supplier of value-added, glazing-focused, interior and exterior products and services. OldCastle and Jet Edge Waterjet Systems, have partnered to install high efficiency abrasive waterjet cutting systems in key operations.

Jet Edge has been at the forefront of designing and manufacturing ultra-high-pressure waterjet pumps and motion systems since the technology came on-line for industrial applications. We take our unique client relationships seriously and are committed to providing configuration solutions that optimize your specific cutting applications in the environment you work in. Learn more at JetEdgeWaterjets.com.

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THIS CASE STUDY

Oldcastle Jet Edge System - Jet Edge Waterjet Systems

OldCastle Building Envelope, Phoenix, AZ pre-shipment at Jet Edge Facility. Installation date August 2022.

PROOFING THE CONCEPT – JET EDGE TEST CUT DATA

Oldcastle approached Jet Edge in an effort to help improve production efficiency and reduce the operating expenses of its abrasive waterjet cutting operation in Schofield, WI. The precision and cut quality their customers demand could not be compromised. The Jet Edge, Edge X3 Mid Rail waterjet cutting system with 3-axis abrasive cutting was the base model chosen as the equipment platform to configure from.

Waterjet Cutting Glass - Jet Edge Waterjet Systems

To proof both the cut quality and productivity of the Edge X3, Jet Edge focused on glass types, thickness and required cut complexity most frequently cut by Oldcastle. By running many test cuts and comparing results to the current production methods being used, Jet Edge and Oldcastle dialed in the optimum setup, resulting in reduced cut times and garnet consumption.

The following optimization information was captured:

  • Sample Materials Cut: .250”, .375”, and .500” thick single pane, 1.170” laminated
  • Orifice/Nozzle Combination: .014/.040 nozzle orifice combination
  • Dual Metered Hoppers: Left hopper used for pierce; Right hopper used for cut
  • Abrasive Flow Rates: Piercing .2 lbs. per minute, Cutting 1.0 lbs. per minute

Pierce rates, circular diameter .055”:

PressureMaterial ThicknessJet Edge Pierce Rate
14,000 psi.250” Single Pane2.0 Seconds
14,000 psi.375” Single Pane3.0 Seconds
14,000 psi.500” Single Pane3.0 Seconds
14,000 psi1.170” Laminate18.0 Seconds

Linear cut rates, quality rating 3, inches per min (ipm):

PressureMaterial ThicknessJet Edge Feed Rate
55,000 psi.250” Single Pane83 ipm
55,000 psi.375” Single Pane52 ipm
55,000 psi.500” Single Pane37 ipm
55,000 psi1.170” Laminate14 ipm

CONFIGURING THE JET EDGE X3 MID RAIL SYSTEM

After proofing the quality of the glass cut finish and beating the current production rate goal significantly, a system was configured in cooperation with the Project Manager for Oldcastle, Schofield, WI.

Key configuration specifications included:

    • An 8’ x 13’ cutting envelope with a mid-rail gantry.
    • A 3-axis cutting head with 12” of Z travel height.
    • 60k psi of cutting pressure with a 50hp drive system.
    • Remote start, boost pump and incoming water control kit.
    • Dual metering hoppers to perform piercing and precision cutting.
    • A bladder catch-tank with adjustable water level.
    • Lexan safety shields.
    • IGEMS programming/nesting software with preconfigured materials and toolpaths, that allows you to begin cutting parts quickly, with higher efficiency after minimal training.
    • An 800lb solid phase abrasive hopper to feed the cutting system.
    • A capital expenditure price that met the ROI goals.
    • An extra year of warranty coverage support.
    • An absolute commitment to ensure this equipment would perform as required post installation.
    • Operator equipment training and post installation support for operation, maintenance, and additional IGEM’s programming support.
    • Direct access to full on-line resources including establishing a MyEquipment link.

“We met Jet Edge through their sister company, Choice Waterjet Parts, an aftermarket parts supplier we used to support our former equipment. Their service levels were first rate, and we quickly learned Jet Edge was not going to stick us with equipment that did not perform. Three more Oldcastle sites, Warrenton MO, Phoenix Az, and Miami FL, followed our lead!”

– PROJECT MANAGER, SCHOFIELD WI

WHEN YOU ARE THE BEST, YOU CHOOSE YOUR PARTNERS CAREFULLY!

FINAL SYSTEM DETAILS

Jet Edge Waterjets Logo - Jet Edge Waterjet Systems and Pumps
Old Castle Cutting Head - Jet Edge Waterjets

Based on the material types, an 8’ x 13” table with a mid-rail gantry system was specified. A single 3-axis cutting head is mounted on the gantry for cutting 2 dimensional shapes to the required accuracy in the x and y plane. (Note: The 5-axis cutting head was determined unnecessary as beveled cuts were not required.) A dual metering hopper is being used to simplify the programming. One hopper is set for piercing and the other set for straight/circular cuts. To download full specifications on the Edge X3, click here.

A bladder option was added to the catch tank that allows the water height to be adjusted manually 2”. This allows for a work piece to be submerged while cutting, reducing both noise and any airborne water particles that bounce from the surface at the start of a cut.

Old Castle Mid-Rail Image - Jet Edge Waterjets
Lexan Safety Shields - Jet Edge Waterjets Systems

Lexan Safety Shields are mounted to all sides of the tank to ensure the work envelope is secured from the operator.

A 60K PSI, 50HP intensifier pump has plenty of horsepower to power the single cutting head. The pump is loaded with many standard features, including remote start, a boost pump, water leakage detector, JetSmart controls and more. To download full specifications, click here.

Hero 50 Pump - Jet Edge Waterjet Systems
Old Castle Hopper - Jet Edge Waterjet Systems

An 800lb Solid Phase Bulk Hopper holds the garnet prior to its delivery to the cutting head.

An additional year of warranty on the pump and motion system was included in the purchase price to ensure worry free support for 24 months. Jet Edge provides additional operator training as required to ensure the system is productive from Day One! Regular Scheduled Maintenance contracts are available along with IGEM’s Contract Programing resources.

  • Built to last icon - Jet Edge Waterjet Systems

    BUILT TO LAST

    Jet Edge Waterjet cutter Motion Systems and Pumps are built right here in the USA and are intended to last longer than our competitors with less downtime.

OLDCASTLE INSTALLATION SITES

Location: Schofield, WI
Installation Date: October 2021

Location: Warrenton, MO
Installation Date: December 2021

Location: Phoenix, AZ
Installation Date: August 2022

Location: Miami, FL
Installation Date: March 2023

The Jet Edge, Edge X3, 8’ x 13’ Mid-Rail Motion System includes a single 3-axis cutting head with a 12” Z travel. The motion system utilizes a Jet Edge HERO 50, with 60k psi and a 50 HP motor system. A two year warranty is wrapped around an equipment price, you would only offer to a committed partner!

ABOUT OLD CASTLE BUILDING ENVELOPE

WHEN YOU ARE THE BEST, YOU CHOOSE YOUR PARTNERS CAREFULLY!

Oldcastle Building Envelope is the leading supplier of value-added, glazing-focused, interior and exterior products and services.

Their experts help architects, glaziers, contractors and owners solve design challenges and bring projects to life. They design, engineer, test and manufacture solutions in engineered curtain wall, storefronts and entrances, architectural glass, shower enclosures, glazing hardware, windows, railings and more.

JET EDGE ON-LINE RESOURCE CENTER

Click the button below to visit our comprehensive Resource Center.

WHAT ARE MID RAIL MOTION SYSTEMS? CLICK HERE TO LEARN ABOUT JET EDGE MID RAIL SOLUTIONS.

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