The Situation: An Unreliable Alternative

A major fertilizer manufacturer, operating under high seasonal demand, faced a critical challenge. After opting to source reformer tiles from a third-party supplier offering an expedited solution, the customer soon experienced significant issues. Despite the quick delivery, the installed tiles began failing in less than a year, well ahead of their intended service life. Cracks appeared. Tiles fell. Tunnel tiles were damaged. The reformer’s reliability was in question. The customer’s operations were at risk, just as prime production season arrived.

The Stakes: Preventing Costly Downtime 

While the customer was in the process of procuring replacement tiles, they faced an unplanned outage, unrelated to the tile failure. We responded immediately, expediting OEM tiles to support a critical repair under intense time constraints. KSPS installed the tiles on-site, enabling the customer to quickly stabilize operations during peak production season. By replacing the broken tiles, the customer avoided the risk of a failed reformer tube or costly downtime that could have resulted in millions of dollars in lost production. 

Why the Failure Happened: Imitation Without Understanding 

The root cause of the failure was twofold: inferior material selection and poor tile design. The non-OEM supplier not only used unsuitable material but also neglected critical engineering details like stress relief features and precise radii. Mouse holes were improperly formed, causing misaligned gas jets and contributing to overall system inefficiency. Worse, the tiles bypassed essential curing protocols, undermining their structural integrity from the start.

Our Response: Engineering That Endures 

John Zink’s OEM tiles are engineered with precision. Every design decision, like adding stress-relief points and exact curvature tolerances, is backed by decades of real-world experience and rigorous analysis. We don’t just manufacture parts. We solve problems. 

  • We understand the materials, including their cure time and structural behavior. 
  • We honor tolerances that others overlook. 
  • We ensure gas jets are aligned and efficient. 
  • And we deliver systems that run better and last longer. 

Immediate Results and Long-Term Confidence 

Now that our OEM tiles are installed, the customer is experiencing: 

  • Restored reformer reliability
  • Minimized risk of unplanned downtime 
  • Confidence in long-term performance 

The results speak for themselves. Since installation, the OEM tiles have delivered reliable performance under demanding conditions reinforcing the critical difference true engineering expertise makes. 

A Collaborative Win

This project showcased more than just speed. It underscored the value of true partnership and the long-term impact of doing things right the first time. When performance and uptime are on the line, cutting corners might seem like a quick fix, but the hidden costs can be enormous. This case is a powerful reminder: every shortcut comes with risks. Choosing precision-engineered OEM solutions means fewer breakdowns, better efficiency, and peace of mind that lasts far beyond installation. That’s the kind of value John Zink is built to deliver.