Processing facilities depend on one thing above almost everything else:

Keeping material moving.

When a critical motor fails, a shaft wears out, a structural component breaks, or a piece of processing equipment goes down, the effects can spread throughout an entire operation.

Electric Machine & Fab provides the industrial repair, machining, fabrication, welding, electric motor, equipment rebuilding, and custom manufacturing capabilities needed to support demanding processing operations.

With facilities in Williamson, West Virginia, and Sidney, Kentucky, EMF helps processing facilities repair critical equipment, rebuild worn components, manufacture difficult-to-source parts, and extend the productive life of existing machinery.

When the process depends on the equipment, the equipment has to work.

Industrial Equipment Repair for Processing Operations

Processing machinery operates in environments where wear is part of the job.

Equipment may face:

• Continuous operation
• Abrasive materials
• Heavy loads
• Impact
• Vibration
• Dust and contamination
• Moisture
• Heat
• Repetitive mechanical stress

Over time, that punishment affects everything from motors and shafts to wear components, fabricated structures, bearing fits, mechanical interfaces, and material-handling equipment.

EMF can evaluate worn and damaged equipment to determine whether components can be repaired, rebuilt, machined, fabricated, modified, or reproduced.

Material Handling Equipment Repair

Material handling systems are often the connective tissue of a processing facility.

When material stops moving, production can quickly follow.

EMF's industrial capabilities can support repair and rebuilding projects involving components associated with conveying, material movement, transfer systems, and other heavy material-handling applications.

Depending on the equipment and project, our work can involve:

• Shafts
• Pins
• Bushings
• Hubs
• Bearing fits
• Mechanical components
• Structural components
• Equipment frames
• Mounting assemblies
• Wear components
• Fabricated sections
• Motor-driven equipment
• Custom replacement parts

Because machining, fabrication, welding, motor repair, and replacement-part manufacturing are available through EMF, we can approach material-handling problems from multiple directions.

Industrial Machining for Processing Equipment

Mechanical wear can slowly reduce the reliability of processing equipment long before a component completely fails.

Shafts wear.

Bores enlarge.

Bearing fits deteriorate.

Pins and bushings lose tolerance.

Mounting surfaces become damaged.

EMF provides industrial machining and CNC machining for both repair work and custom replacement components.

Capabilities can support projects involving:

• Shaft repair and manufacturing
• Pins
• Bushings
• Sleeves
• Hubs
• Bores
• Journals
• Bearing fits
• Housings
• Mechanical interfaces
• Custom machine parts
• Replacement components
• Fabricated-and-machined assemblies

When a component can't be repaired economically, our machining capabilities can also support manufacturing a replacement.

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Electric Motor Repair for Processing Facilities

Processing plants depend heavily on electric motors.

Motors drive equipment throughout material handling, production, and processing operations, and a major motor failure can quickly become a production problem.

EMF provides industrial electric motor repair and rebuilding backed by machining and electromechanical capabilities.

Our Williamson facility is a major center for this work, particularly for substantial industrial motors and applications requiring both electrical and mechanical repair capabilities.

When the project also involves a damaged shaft, worn bearing fit, housing, or other mechanical component, EMF's machine-shop capabilities can become part of the repair.

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Electromechanical Repair

Processing equipment often sits directly at the intersection of electrical and mechanical systems.

The motor may be electrical.

The equipment it drives is mechanical.

The problem can involve both.

EMF provides industrial electromechanical repair for motors, rotating equipment, and related components, with machining capabilities available when worn mechanical features need to be restored.

That integrated approach can be particularly valuable when the exact source of an equipment problem isn't limited to one side of the system.

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Power Transmission Repair

Power has to travel from the motor to the equipment doing the work.

That makes shafts, couplings, hubs, bearing fits, drive components, and mechanical connections critical parts of many processing operations.

EMF provides power transmission repair support backed by industrial machining, mechanical component repair, and replacement-part manufacturing.

When older drive components become difficult to obtain, our reverse-engineering and machining capabilities may also provide another route to restoring the equipment.

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Heavy Fabrication & Welding

Processing facilities contain far more than rotating machinery.

Heavy steel structures and fabricated equipment are often fundamental parts of the operation.

Over time, abrasion, corrosion, impact, vibration, and continuous use can damage those structures.

EMF provides heavy industrial fabrication and welding for repair, rebuilding, and custom manufacturing projects.

Our fabrication capabilities can support:

• Equipment frames
• Structural components
• Heavy mounting assemblies
• Equipment bases
• Wear areas
• Replacement steel sections
• Custom brackets and supports
• Fabricated equipment components
• Repair assemblies
• Structural reinforcement
• Custom industrial fabrications

Fabricated components requiring precision mechanical features can then move into EMF's machining operations.

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Heavy Plate Processing

Some processing equipment is built from substantial steel.

EMF's Sidney facility gives customers access to significant plate-processing capabilities through our large-format Messer CNC cutting system.

The system features a 10-foot by 30-foot cutting table, allowing EMF to process large steel components and fabrication blanks.

For appropriate materials and applications, EMF can process heavy plate in the 8- to 10-inch thickness range.

That capability can support:

• Wear components
• Heavy equipment sections
• Structural replacement pieces
• Fabrication blanks
• Equipment bases
• Mounting plates
• Custom industrial components
• Heavy repair sections

After cutting, material can continue through fabrication, welding, machining, assembly, and finishing as the project requires.

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Wear Components & Abrasion-Related Repairs

Processing abrasive materials eventually takes steel with it.

Wear areas become thinner.

Edges disappear.

Surfaces deteriorate.

Equipment loses material.

Eventually, a component that began as substantial steel can reach the point where continued operation becomes impractical.

EMF can evaluate worn processing equipment and determine whether damaged areas can be rebuilt, resurfaced, reinforced, replaced, or reproduced.

Our combination of heavy welding, plate processing, fabrication, and machining gives us multiple ways to approach equipment exposed to severe wear.

Custom Replacement Parts

One small unavailable component can create a very large production problem.

This is especially common with older or specialized processing machinery.

The equipment may still be perfectly capable of doing its job while the original replacement parts become:

• Obsolete
• Discontinued
• Difficult to source
• Subject to excessive lead times
• Available only as part of a larger assembly

EMF can manufacture custom industrial replacement components using machining, fabrication, plate processing, and reverse engineering.

Depending on the project, we can work from drawings, specifications, existing parts, samples, and available equipment information.

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Reverse Engineering for Older Processing Equipment

Processing facilities often keep machinery in operation for decades.

That's a good thing—until a critical part fails and nobody has a drawing.

Reverse engineering can help bridge that gap.

EMF can evaluate an existing component and available technical information to help establish the dimensions, geometry, interfaces, and requirements needed for repair or reproduction.

Once those requirements are understood, the component can move directly into our manufacturing operations.

Existing Component → Analysis → Manufacturing Plan → Machining/Fabrication → Replacement Part

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Equipment Retrofitting & Modernization

A processing machine doesn't necessarily need to be replaced simply because one component has become obsolete.

Sometimes the practical answer is modifying the existing equipment.

A replacement motor may require a different mounting arrangement.

A new mechanical component may require an adapter.

An older structure may need reinforcement.

A discontinued component may require a custom replacement.

EMF can combine engineering, machining, fabrication, and electromechanical capabilities to support equipment modifications and modernization projects.

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Equipment Rebuilding

Processing equipment doesn't always fail all at once.

Years of operation can gradually wear multiple areas of a component until a simple repair is no longer enough.

In those situations, a more substantial rebuild may be appropriate.

EMF can combine:

Disassembly + Welding + Fabrication + Material Replacement + Machining + Replacement Parts + Assembly + Finishing

to restore heavy industrial components where practical.

Our ability to perform multiple processes under one organization can be particularly valuable when a rebuild crosses the boundaries between a machine shop, fabrication shop, and repair facility.

Supporting Aggregate & Bulk Material Processing

Operations handling coal, stone, aggregate, minerals, raw materials, and other bulk products can place severe demands on processing and material-handling equipment.

Abrasive materials accelerate wear.

Heavy loads increase mechanical stress.

Impact damages structures and wear components.

EMF's experience serving heavy industry makes our capabilities a strong fit for equipment operating in these demanding environments.

From heavy fabrication and machining to motors, replacement components, and equipment rebuilding, we can support the parts of the operation that take the punishment.

Supporting Industrial Production & Process Equipment

Not every processing facility handles rock or coal.

Many manufacturing and industrial operations rely on specialized processing machinery that faces its own mechanical challenges.

EMF can support projects involving production equipment, material handling systems, motor-driven machinery, mechanical components, structural assemblies, and custom industrial equipment.

The specific machinery changes from plant to plant.

The fundamental problem doesn't:

Critical equipment has to stay productive.

Repair, Rebuild or Reproduce?

When processing equipment fails, the answer isn't automatically "buy another one."

The practical solution may involve:

• Repairing the original component
• Rebuilding worn areas
• Machining critical surfaces
• Replacing damaged steel
• Fabricating a new section
• Manufacturing an obsolete part
• Reverse engineering an existing component
• Modifying the equipment
• Building a replacement assembly

Because EMF provides both repair and manufacturing capabilities, we can evaluate several possible paths instead of forcing every project into the same process.

One Industrial Resource for Complex Repairs

Processing equipment repairs can become complicated quickly.

A single component may need:

Engineering → Plate Cutting → Fabrication → Welding → Machining → Replacement Parts → Assembly → Finishing

Coordinating those processes across several different vendors can make an already difficult repair more complicated.

EMF brings many of those capabilities together under one company.

That means the project can move from one industrial discipline to another without leaving the broader EMF operation.

Two Facilities Supporting Processing Operations

Electric Machine & Fab operates two complementary facilities.

Williamson, West Virginia

10 Industrial Drive
Williamson, WV 25661

Williamson provides significant capabilities in:

• Industrial electric motor repair
• Electromechanical repair
• Industrial machining
• Mechanical component repair
• Equipment rebuilding

Sidney, Kentucky

15400 Bent Mountain Road
Sidney, KY 41564

Sidney provides substantial capabilities in:

• Heavy industrial fabrication
• Industrial welding
• CNC and industrial machining
• Large-format CNC plate cutting
• Heavy equipment rebuilding
• Custom component manufacturing

Together, these facilities allow EMF to support everything from motor-driven processing equipment to massive fabricated steel components.

Serving Processing Facilities Regionally and Nationwide

Electric Machine & Fab serves industrial customers throughout:

West Virginia • Kentucky • Virginia • Ohio • Tennessee • Pennsylvania

Our reach also extends nationwide.

Motors and repairable components can be transported to our facilities. Existing parts can be sent for evaluation. Drawings and specifications can be provided for custom manufacturing projects. Finished components can be shipped throughout the United States.

Whether the processing facility is in Appalachia or across the country, EMF can provide industrial capabilities for equipment that needs more than an off-the-shelf solution.

Keep the Material Moving.

Processing facilities don't make money when critical equipment is sitting still.

Whether you're dealing with a failed motor, worn shaft, damaged material-handling component, cracked fabrication, obsolete replacement part, or heavily worn piece of processing equipment, Electric Machine & Fab can help determine the practical path forward.

Bring Us the Equipment That's Holding Up the Process

Tell us what's failing.

Send us the drawing.

Bring us the worn component.

Or show us the piece of equipment you're trying to keep alive.

With industrial machining, fabrication, welding, electric motor repair, equipment rebuilding, reverse engineering, and replacement-part manufacturing available through one company, EMF is built to help keep industrial operations moving.

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