At Gates Albert, our case studies highlight how advanced machining, cleaning, and inspection solutions solve real manufacturing challenges. From cutting production costs with Davenport Hybrid technology to eliminating defects with vision inspection systems, these success stories show how we help customers improve efficiency, reduce waste, and deliver zero-defect parts at scale.
Browse the case studies below by clicking on each title to expand and read the full story.
A process plagued by brazing defects was costing one customer significant time and money. By integrating the DURR Ecoclean Parts Cleaning System, Gates Albert eliminated contamination, removed re-cleaning steps, and improved brazing joint reliability to 100%.
Quick Stats
- Removed 18% defect rate caused by poor cleaning
- Eliminated re-cleaning labor
- Improved brazing joint consistency
The Challenge
A customer’s brazing process had an 18% failure rate due to contaminated parts, requiring repeated cleaning and slowing throughput.
Our Solution
By introducing the DURR Ecoclean Parts Cleaning System, parts were cleaned and dried in a vacuum-proof chamber, ensuring pristine brazing surfaces.
Results
- Zero brazing fallout
- Eliminated re-cleaning steps
- Improved overall product quality
Common Questions
• Why is cleaning critical for brazing?
Contaminants on metal surfaces prevent proper bonding, causing costly failures. DURR Ecoclean ensures total cleanliness.
• What contaminants does DURR Ecoclean remove?
It eliminates oil, dirt, fine dust, and residues that interfere with brazing and bonding processes.
• How does vacuum cleaning improve brazing joints?
Vacuum cleaning ensures a perfectly clean metal surface, allowing for stronger, defect-free brazing bonds.
➡️ Learn more about how industrial cleaning systems improve reliability and eliminate downtime.
Downtime in injection molding often starts with jammed feeders. Gates Albert used the DURR Ecoclean system to eliminate chips, dust, and debris that disrupted automated bowl feeding, cutting maintenance costs and improving molding quality.
Quick Stats
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Eliminated bowl feeder jams
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Reduced maintenance costs
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Improved molding quality
The Challenge
Chips and debris jammed automated bowl feeders, causing downtime and repair costs in plastic injection molding.
Our Solution
Gates Albert applied the DURR Ecoclean system, removing debris and ensuring only clean parts reached feeders.
Results
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Zero feeder jams
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Lower repair costs
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Higher-quality output
Common Questions
How does cleaning prevent feeder jams?
Removing debris ensures uninterrupted flow, minimizing downtime and protecting equipment.
What contaminants most often cause injection molding feeder jams?
Dust, plastic shavings, and leftover machining debris are the most common culprits. Regular cleaning prevents these from blocking feeders.
Can Ecoclean systems improve long-term equipment life in molding operations?
Yes. By keeping feeders free from buildup, Ecoclean systems reduce wear and tear, extend service intervals, and lower repair costs.
➡️ Discover how parts cleaning solutions can optimize your injection molding process.
Machining stainless steel parts hardened above 50 HRC is no easy task — especially at high volumes. Gates Albert applied Davenport Hybrid Machine capabilities to cut cycle times by 80% and deliver flawless parts from a custom alloy, showing how hybrid processes excel even with the toughest materials.
Quick Stats
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Processed stainless steel above 50 HRC
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Cut production time by 80%
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Achieved highest-quality parts to date
The Challenge
A custom stainless steel material solved field failures but proved difficult to machine in high volumes. Standard single-spindle machines couldn’t keep up with demand.
Our Solution
Using the Davenport Hybrid Machine, Gates Albert developed a process that handled tough materials efficiently while maintaining precision.
Results
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80% faster production cycles
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Increased machine availability
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Quality engineer praised parts as “the best we’ve ever seen”
Common Questions
Can hybrid machines handle high-hardness materials?
Yes, with CNC-driven accuracy, hybrid Davenports machine hard metals reliably at high volumes.
Can Hybrid Davenport machines handle hardened alloys reliably?
Yes, the CNC control ensures accuracy and consistency, even when machining metals above 50 HRC.
How does hybrid machining increase throughput on tough materials?
The process reduces tool changes and integrates multiple steps, boosting efficiency by up to 80%.
➡️ Learn how our machining expertise delivers results on the toughest materials.
At Gates Albert, we helped a manufacturer transform production by consolidating four separate machining operations into a single process. Using our Davenport Hybrid Machine, the customer reduced costs by more than 50%, cut scrap dramatically, and sped up lead times — proving the power of hybrid machining in today’s competitive market.
Quick Stats
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Consolidated 4 operations into 1
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Reduced per-part costs by 53%
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Lead times improved dramatically
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Scrap costs cut significantly
The Challenge
A customer faced mounting scrap costs and slow lead times caused by multiple secondary machining processes. They risked abandoning an entire product line unless efficiency improved.
Our Solution
By leveraging the Davenport Hybrid Machine, Gates Albert consolidated four separate operations across multiple locations into a single machine setup. This innovation cut costs, streamlined scheduling, and enhanced product quality.
Results
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53% per-part cost savings
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Stronger profit margins
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Faster turnaround times
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Customer increased market share
Common Questions
How does the Davenport Hybrid Machine reduce scrap costs?
By consolidating operations, fewer handling steps are required, which reduces error rates and cumulative scrap.
What industries benefit most from Davenport Hybrid machining?
Automotive, aerospace, and medical manufacturers save time and costs by consolidating multiple machining steps into one hybrid process.
Can the Davenport Hybrid Machine improve lead times for small batch runs?
Yes. By reducing setup and transfer between machines, hybrid machining shortens lead times even on low-volume production.
When faced with choosing between costly CNC and rotary transfer machines, a customer turned to Gates Albert for a smarter solution to reduce equipment costs. Our Davenport Hybrid Machine technology delivered precision and efficiency at a fraction of the cost, while saving floor space and simplifying operator training.
Quick Stats
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Saved 67% on machine investment
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Reduced floor space requirements by 50%
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Simplified employee training
The Challenge
A new product launch required a complex component. Options included a $1M rotary transfer machine or a CNC automatic lathe, both costly and space-consuming.
Our Solution
Gates Albert provided a Davenport Hybrid Machine, at 1/3 the cost and half the footprint of alternatives. Operator training was simplified using an intuitive CNC touchscreen interface.
Results
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Cost-effective production launch
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Lowered barriers to employee training
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Conserved floor space
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Met target price points
Common Questions
Why choose a Davenport Hybrid Machine over a CNC lathe?
Davenport Hybrid machines deliver CNC precision with mechanical efficiency at a fraction of the cost and footprint.
How does a Davenport Hybrid Machine compare to other rotary transfer machines?
It delivers similar precision at a fraction of the cost, with a smaller footprint and easier operator training.
Is operator training easier on Davenport Hybrid equipment?
Yes. With touchscreen controls and CNC integration, training times are much shorter compared to large rotary systems.
For a customer demanding zero defects across millions of parts, Gates Albert implemented the Automated Retina Vision Inspection System. This solution verified every feature on every part, guaranteeing 0 PPM performance while increasing throughput fivefold.
Quick Stats
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100% verification of all features
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Achieved 0 PPM across millions of parts
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5X throughput of production machine rate
The Challenge
A customer demanded 0 PPM defects — even a few per million was unacceptable.
Our Solution
Gates Albert deployed the Retina Automated Vision Inspection System, verifying multiple features on every part in real time.
Results
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Guaranteed zero defects
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Increased throughput 5X
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Delivered consistency across millions of parts
Common Questions
What makes vision verification superior to manual checks?
Automated vision inspects every part instantly, removing human error and guaranteeing accuracy..
Can vision inspection replace manual quality checks?
Yes, automated vision systems provide faster, more accurate, and 100% consistent verification.
How scalable is automated vision inspection?
Vision systems can handle millions of parts without sacrificing accuracy, making them ideal for high-volume production.
➡️ Learn how our automated vision systems can bring your defect rate to zero.
Injection molding downtime caused by contaminated feeders was draining productivity. Gates Albert solved the problem with the Retina Vision Inspection System, which sorted and verified parts before assembly, preventing jams and ensuring reliable output.
Quick Stats
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Eliminated feeder jams from contamination
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Reduced downtime and repair costs
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Guaranteed only correct parts were assembled
The Challenge
An injection molding operation suffered frequent feeder jams from contamination and mixed parts, reducing efficiency and quality.
Our Solution
Gates Albert applied the Retina Vision System to inspect and sort parts before they reached the feeder, ensuring only the correct components entered production.
Results
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Zero jams
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Fewer maintenance costs
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Reliable, error-free molding
Common Questions
Can vision systems improve assembly accuracy?
Yes, they ensure only verified, correct parts are used, eliminating costly downtime and rework.
How do vision inspection systems detect incorrect parts?
High-speed cameras and pattern recognition software compare each part against specifications, rejecting defective or mismatched pieces instantly.
Can automated vision reduce overall production costs?
Yes. By preventing jams, rework, and downtime, vision systems cut labor costs, extend equipment life, and keep production schedules on track.