Switching from Metal to MC Nylon for Durable, Cost-Effective Parts

Background Information

A client in the confectionery manufacturing industry approached Yumoto Electric with a recurring issue. A roller part made from aluminum alloy in their production line had worn out and broken during operation, leading to production downtime and repeated replacements. The customer wanted to develop a more durable alternative that could handle continuous use while maintaining performance.

Problem Statement

At first, the customer assumed the best solution was to switch to a stronger metal material. However, that approach would likely increase both weight and production cost, while offering limited improvement in wear resistance. The challenge was to find a material and machining process that could balance durability, cost, and food safety.

Solution Implementation

After reviewing the part’s function and operating conditions, Yumoto Electric proposed changing the roller material from aluminum alloy to MC Nylon, a type of engineering plastic known for its excellent wear resistance and machinability.

To ensure compliance with the Food Sanitation Act, the MC Nylon components were treated through a boiling sterilization process so they could be safely used in food-contact environments. Because MC Nylon does not require surface coating, the manufacturing process was simplified, resulting in lower costs and lighter parts.

While metals generally offer higher strength than plastics, the mechanical load of this particular roller was well within MC Nylon’s performance range. This allowed the customer to maintain durability without resorting to expensive super engineering plastics.

Results

By switching from metal to plastic, the customer achieved a lighter, more durable, and more cost-effective roller. The MC Nylon part offered excellent wear resistance and stable performance, reducing maintenance needs and improving overall production reliability.