Fabrication of Obsolete and Necessary Parts

When critical components become obsolete, operations shouldn’t have to stop—however, solutions must be found. At times we have been called on for the fabrication of obsolete and necessary parts.  At TMW Systems, LLC, we partnered with a large industrial sulfur distribution company to design and manufacture three essential parts and assemblies, saving the client both time and significant capital expenditures.

All components were fabricated using 316 stainless steel, selected specifically for its corrosion resistance due to the plant’s proximity to the Pacific Ocean and the corrosive nature of the sulfur material handled by the conveyors. The choice of material was strategic, ensuring longevity and safety under harsh environmental and chemical conditions.

Keeping the conveyor operational at a surlfur plant

Project 1: Custom Scraper Blades for Conveyor System:

Our first engagement involved engineering replacement scraper blades for the company’s aging conveyor system. These parts were no longer supported by the OEM and had begun to wear significantly over time.

TMW Systems was chosen because we could manage the entire process—from design to production. We began by drawing bar over mandrels to create the spring assemblies, followed by tapping the springs for nuts and holddowns. We then fabricated and welded the blade assemblies, including the attachment plates.

By reverse-engineering and rebuilding these scraper blades, we enabled the client to continue operating their existing conveyor system without the need for a full system retrofit. According to the client, our solution avoided a capital expense of over $100,000—a result of effective collaboration and our end-to-end manufacturing capabilities.

Location of the gearbox at the site

Project 2: Gearbox Assembly and Motor Replacement:

The second challenge involved a worn gearbox assembly on one of the primary drive conveyors. The unit had reached the end of its lifecycle, and the original manufacturer no longer offered replacements. To complicate matters, the motor had seized, requiring a full assembly replacement.

TMW Systems engineered a new gearbox with custom spindles and bearings. The internal gears were commercially available and key-installed to ensure long-term serviceability. A new motor featuring an electric brake was sourced and coupled with the gearbox, creating a complete drive assembly.

All work was performed in compliance with Management of Change (MoC) requirements, and the system was seamlessly brought back online—where it remains in operation today.

Project 3: Sidestream Conveyor Rebuild Under Tight Timeline:

The third and most urgent project involved a sidestream conveyor on the primary feed line. The existing unit was failing, and a full facility shutdown was looming. Due to strict MoC compliance requirements—standard across refineries and chemical plants—a near-exact duplicate was mandated in terms of materials, dimensions, and functionality.

We mobilized quickly, visiting the site to take precise measurements. Locating obsolete materials demanded a nationwide search, but we succeeded in sourcing every required component. The result was a fully reconstructed sidestream conveyor, identical to the original.

Thanks to our attention to detail and commitment to precision, the client’s maintenance team was able to install the new unit in just a few hours. Everything fit perfectly, minimizing downtime and restoring operations without disruption.

Conclusion: Solving the Unsolvable:

At TMW Systems, we specialize in building the parts that others can’t—or won’t. From legacy machinery to one-of-a-kind systems, we find a way to bring your equipment back to life.

Our services are ideal for:

• Refineries and chemical processing plants that must meet Management of Change (MoC) compliance

• Manufacturing and industrial facilities relying on legacy equipment with no OEM support

• Distribution centers and logistics operations where conveyor downtime means profit loss

• Energy and utility providers operating in harsh environments where custom solutions are essential

• Rock, sand, and aggregate quarries with high-demand, abrasion-prone systems that require durable and often custom-engineered parts

• Pulp, paper, food processing, and mining industries, where specialized materials and safety standards are non-negotiable

Whether you’re trying to source hard-to-find materials, rebuild discontinued components, or meet strict regulatory standards, we go the distance—literally—to keep your operation up and running.

👉 Need a custom solution for an obsolete part or failing equipment? Contact us today and let’s talk.