Case Study: Borusan Pipe USA Streamlines Operations with Custom Thread Protection

Borusan Pipe USA, a leading steel pipe manufacturer, recently opened a stretch reduction mill at its Baytown, Texas facility. The mill produces ASTM standard pipe with threaded ends that require protection during handling, shipment and storage.

Borusan set out to find thread protection that met several of its requirements. First, it wanted to replicate the thread protection already used at its Turkish facility, and second, wanted a protection solution that would work well with the automated manufacturing equipment installed at the new mill.

After exploring several options, Borusan chose to work with Caplugs to develop custom caps and plugs. These custom parts not only met Borusan’s protection and manufacturing needs but allowed for greater brand recognition and quick turnaround times, with both the caps and plugs being made in the U.S.

In this case study, we will explore the challenges Borusan faced at the outset of its project, how a partnership was created with Caplugs, and how the partnership ultimately led to a custom solution that checked every box from a protection and manufacturing standpoint.

Initial Challenge

When Borusan began its search, it initially tried off-the-shelf caps and plugs but quickly realized custom protective products would lead to a better result.

“Some off-the-shelf products we tried didn't fit exactly like we wanted because pipe size can vary from mill to mill," said Dhaval Trivedi, Vice President of Supply Chain at Borusan. “Every mill has some variation, and we wanted consistency and a very specific product so our process and application are always streamlined.”

With that knowledge, the Borusan team set out to find a manufacturer that could better meet its needs with caps and plugs that more closely resembled those from its Turkish facility. 

Finding a Trusted Partner in Caplugs

Already having a business relationship built with Tri-Star Protectors (a sister company of Caplugs), Trivedi had knowledge of what Caplugs provided in terms of custom product protection. He had even spoken with the Caplugs team previously when working on different projects, so he knew there was an opportunity. He began discussing this new project with a local Caplugs industrial account manager, whom he had spoken with prior. 

The initial discussions went well, and from there, Trivedi and Borusan technical teams began working with Caplugs to develop the new, custom protection for the threaded ends of the ASTM pipe, with prototyping beginning almost immediately.

From Development to Deployment

The initial prototyping and development process took roughly six months with various design iterations, testing and tooling done for each part. 

“We went back and forth and did multiple prototypes of both the caps and the plugs to get things where they needed to be,” Trivedi said. “We realized there was a certain design we would need for each, and it was a matter of getting it right.”

To “get it right,” Caplugs engineers worked tirelessly to create a properly adjusted taper for the plug design that would attach easily and provide the correct fit. Although there were several design iterations and different dimensions tried, Borusan was ultimately satisfied with the final version of the tapered plug.

There were also multiple iterations of the custom cap made before a final design was approved, to ensure it would grab onto and cover all threads properly and stay on securely. To achieve this, the Caplugs team created variations of several of its catalog caps that were longer and featured thicker walls with more ribs.

Borusan was extremely pleased with the final versions of the custom caps and plugs as they fit well and protected all threads as required. It was equally satisfied with the way these new parts worked with its automated manufacturing systems.

“With the automatic installation, dimensional tolerances are extremely important," Trivedi said. “We couldn't afford anything too loose or too tight since we're automatically applying them to the pipe without manual adjustment. We were very happy to get these new parts that worked well from an automated standpoint.”

Quality That Puts the Customer First

Overall, Borusan was very happy with the resulting parts as they now have a consistent product they can trust for proper thread protection. 
“We knew it would take some time at the outset because we had to finalize the design and develop the custom tooling," Trivedi said. “But the beauty of it is we now have custom products that are systematic, and we know exactly what we're going to buy each time.” 

As an added benefit, the partnership allowed for important branding to be engraved on the caps and plugs as part of Borusan’s brand strategy for the American market. 

“It's also about our own brand recognition,” Trivedi said. “So, if somebody looks at the end of the pipe and the cap or plug, they can see our logo engraved on it. We don't want our pipe to have just anything standard that anybody else has. We want it very specific to us, custom to us, with our name and the colors that we want on it.”

US Made to Meet Goals & Improve Lead Times

The partnership also aligned with Borusan's commitment to domestic manufacturing for the pipe made at the new stretch reduction mill.

“Our goal is to have everything made in the USA for our standard pipe,” explained Trivedi. “We buy 100% U.S. domestic steel, make pipe here fully processed, buy couplings locally, and wanted to have these protectors made in the U.S. This product line is what we call 'melted and made in USA' with accessories.”

With the custom caps and plugs made in the U.S. by Caplugs, Borusan met its strategic goals and found added benefits with improved time to market and flexibility in ordering. 

“We wanted to improve delivery lead times and get    the product to the customer in three to five days maximum,” said Trivedi. “We keep some stock on hand and the Caplugs team has some on hand for when we need more. That makes replenishment much quicker and it's ultimately a better outcome for our customers.”

In Trivedi’s eyes, getting a quick turnaround time for its caps and plugs was the key factor for working with a U.S. supplier. 

“Three to five days versus the three months or more you get from overseas suppliers makes all the difference and makes us very excited to be working with Caplugs,” Trivedi noted. 

More Than Just Thread Protection

The success of this project has created a healthy relationship between Borusan and Caplugs, with the companies maintaining regular communication that may ultimately lead to additional opportunities.

“The Caplugs team come and visit every other month or two to see how we can continue growing the partnership,” said Trivedi. “The overall experience has been very positive and we look forward to our continued relationship.”

Protection Solutions Tailored to Your Needs

Looking for custom product protection like we’ve developed for Borusan Pipe USA? 

Our experienced sales and engineering teams specialize in working with customers to create custom solutions that integrate seamlessly with products and processes.

Whether it be specific dimensional needs, custom branding or any other requirements, we work closely with customers to understand their unique challenges and develop solutions that improve efficiency and reduce costs.

Just as we did for Borusan, we can help you find the right custom solutions to enhance your operations and support your business goals.

For more information on how Caplugs can enhance product protection, visit our custom capabilities page or contact a team member directly at 1.888.CAPLUGS.

When you need a custom protective part for a unique need, let the largest, most experienced in-house team of design engineers develop it for you from initial design to final production. We offer extensive custom molding solutions to meet your cost, performance, and production requirements

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