Xtek, Inc.

Xtek Inc. is a manufacturer based in Cincinnati, Ohio, specializing in the production of components for the steel industry, including crane wheels, brake wheels, loose gearing and geared couplings for rolling mills. Founded in 1909, the company began as a manufacturer of gears for traction cars. Xtek established its position as a manufacturer through the production of components using its proprietary heat treatment process called the “Tool Steel Process (TSP)”, and expanded its business to applications such as railways, coal mines, and steel mills.

In 2005, under the leadership of Vice President Roger Miller (the current CEO), the company made significant capital investments to enhance production capacity. To accommodate diverse product lines and small-lot production, the company introduced Mazak’s INTEGREX i-800V/8 multi-tasking machine and PALLETECH, a pallethandling automation system.

Marketing Director Kris Tegeder says, “At first, we thought that automation could not be applied to a high mix/low-volume shop like us, with job lot sizes ranging from one to eight parts. We soon discovered that this multi-tasking machine and automation system was the solution for incorporating lights-out machining.” Terry Emerson, Production Department Manager, says, “The INTEGREX i-800V/8’s turning, milling, and drilling capabilities allow us to eliminate the need for parts to travel from one machine to another, which greatly reduces the amount of setup time required.”

For the PALLETECH system, Xtek utilizes its 16 pallets and one loading station by automatic loading / unloading of various-sized parts that range from 1” - 30” in size to the machine tool. This allows offline setup while the machine is running and enables unmanned night production, which is expected to result in a 15 - 20% reduction in overall manufacturing cycle time.

With its proficiency in heat treatment / metallurgy and its ability to incorporate heat treatment into the manufacturing process, the company currently generates a significant por tion of its sales from the steel industry. Among the products manufactured for the steel industry, gear couplings are notable for Xtek, due to the long history the company has with them and because Xtek focuses not only on new product development but also on repair and maintenance for the product. The company’s reconditioning service, which includes improvement of par t design and refining of its manufacturing techniques to make end products even better, is highly regarded by many companies that operate rolling mills.

Currently, most of Xtek’s sales consist of products for the steel market, with domestic products accounting for the majority of those sales. In the United States, which produces approximately 116 million tons of steel annually, production volume and equipment utilization rates have remained flat in recent years, but steel production bases and production methods are beginning to undergo major changes, and manufacturers are required to adapt to these changes.

The company’s slogan is “Solutions in Motion.” To embody this slogan, Xtek is actively engaged in both product development and reforming of the production system, and is manufacturing with a view to the next product design and improvement. The company will continue to adapt flexibly to the ever-changing industry and expand its business opportunities.