As a company we oversee the whole process from initial specification and design through manufacture to delivery. Ferrabyrne have an unusually high proportion of design and development workforce working alongside both experienced and younger engineers. This results in a good cross-section of skills and an exceptionally wide range of experience for our customers.
For new applications we work in conjunction with customers from their initial concepts to end result. We will consider any design and development project either for customer specific specifications or for engineering exercises. Our aim being to offer products that increase product life with minimum life cycle costs.
Product development is an important part of our work and all of our products do undergo considerable testing during the product proving processes. Our full test house facilities are generally used for internal purposes but there are occasions when Ferrabyrne are asked to test other products.
We have a wide range of equipment including linear tension and compression testing machines along with a 6×6 metres six channel test rig to test suspension sub assemblies. Ferrabyrne offer strain gauging, data processing and test rig design to a range of industries and chemical compound analysis is also available. Side by side fatigue testing is used to quantify the benefits of any new or modified design. All newly designed parts are tested to ensure that the characteristics meet or exceed the specification.
Parts are also tested as part of the batch release process. Our test facilities are used to regularly test our own products for compliance.
Our manufacturing facility of approximately 3,000 sq.m contains a variety of plant and equipment including 32 Vulcanization Presses ranging from 100 – 1000 Tonne, 2 Rubber Mills, a fully ventilated Bond Painting facility, an assembly and finishing area for all types of bushes, a complete overhaul/assembly section dedicated to the refurbishment and new build of various assemblies, including Traction Centres, Anti-Roll Bars and associated links, and Airspring assemblies.
A Paint Shop for all types of paint and finishes.
In addition, we have a separate warehouse of approximately 1,400 sq.m used for storage, including an inspection area for goods-inwards and dispatch. Goods are inspected, packed, stored and dispatched to the highest industry standards.
Tooling Design & Manufacture
Mould tools are designed and maintained in-house by the Ferrabyrne team which enables simultaneous engineering and development within the shortest possible lead time.
Our use of our 3D CAD CAM facility allows the 3D data to aid the design and manufacture of tooling, which makes it cost effective for the customer. We produce designs for specialist prototype and development single cavity and multi-cavity production tools using our CNC machining capabilities.
As an OEM supplier to the rail industry we offer a structured set price refurbishment service for parts, these parts are returned looking as new. This is a more attractive option than buying new parts – particularly for high-metal objects as the metal areas are designed for life. It is a cost-effective way to keep the trains running.
Ferrabyrne collect the used products, bring them back to our facilities and blast out the rubber to metal components. We then clean them, replace with new rubber, paint and deliver the parts back to the customer one week later. Rubber is burnt via pyrolysis as an inert process so there is no damaging environmental impact. Any need for the customer to hold multiples of the same spare parts is negated and there are no time delays caused by disassembly and re-assembly. This is a full refurbishment process, please contact us for specific details.
As with most industries and particularly within the rail and wind turbine markets, quantified life expectancies and costs of both existing and developed products are of great importance. Extending periods between services can reduce the number of services and hence decrease operating costs.
After a product has reached its predicted life span, we inspect it, and test it to assess the part for future use. Condition assessment for mileage extension is an important area for us and where service life and condition can be fed back into our design processes and calculation with the aim of increasing life span and reducing life cycle costs.