Marathon Pac TM total MIG/MAG efficiency. Bulk wire systems for non- and low-alloyed steel, stainless steel and aluminium.

Marathon Pac TM total MIG/MAG efficiency. Bulk wire systems for non- and low-alloyed steel, stainless steel and aluminium.

ESAB Marathon Pac TM More efficiency and savings. By kind permission of ABB The welding wire your robots have been waiting for. OK ARISTOROD A NEW GENERATION OF BARE MAG WIRES AristoRod bare MAG wires with advanced surface characteristics (ASC) and Matt Stainless MIG wires are both examples of ESAB s new advanced wire products that are available in Marathon Pac. We made this wire matt so your productivity can shine. NEW! MATT SURFACED STAINLESS STEEL MIG WELDING WIRE. Downtime is costly and its two biggest causes - wire spool change and feed problems - can both be cut with the ESAB Marathon Pac bulk wire system. Each drum of quality wire has many times the volume of a spool or coil. So with fewer changes and greater process stability you gain increased product output and quality. You also save in wire handling, simplified installation and disposal of drums. The Marathon Pac family includes high quality wires for steel, stainless steel, aluminium and MIG-brazing, the ESAB range of Advanced Welding Wires (OK AristoRod, Matt Stainless and a new generation of aluminium wires), non and low alloyed cored and SAW wires, and stainless cored wires. Gain a whole new world of savings Marathon Pac delivers savings right along the MIG/MAG and SAW production chain - from manual through to robotic applications irrespective of local labour costs. Marathon Pac promotes lean manufacturing through reduced downtime, process stability weld quality efficient consumables handling. Save on MIG/MAG downtime You could cut spool change downtime by almost 95% when compared to the use of 18 kg spools, giving more arc time with fewer workflow interruptions. Save on post-working and rejects Frequent and abrupt spool wire ends risk faulty welds. Feed problems can also result in rejects or costly post rework. Each Marathon Pac is filled using a special reverse coiling technology to ensure wire comes out straight and perfectly positioned, for greater process stability and a significantly reduced risk of spatter. Save on feeder wear and other replacement parts With no revolving spools and straighter wires there is less wear of machine parts and feeders. Save on handling time and spool disposal costs Built-in lifting straps and a range of accessories simplify on-site handling from goods-in to the workstation. Once empty, the octagonal drum packs flat to save space and ease disposal. What s more, Marathon Pac is 100% recyclable. - for lean manufacturing applications.

Savings right along the entire MIG/ MAG production chain. With Marathon Pac there are savings right along the MIG/MAG production chain. Even in lower labour cost countries, Marathon Pac will save a minimum of nine eurocents per kilogram on downtime alone, and that s before you have added in all the other benefits. Even if you have just a few manual stations, Marathon Pac can still save you money. If your plant is fully mechanised, or you have invested in robot stations, then cutting downtime is more important than the cost of the consumables. That s when ESAB s Endless Marathon Pac really comes into its own. Typical cost savings for professional users - Marathon Pac vs 18 kg spools Low labour cost environment High labour cost environment This overview is based on actual tests and reports obtained from Marathon Pac users from various branches of industry. Highly mechanized environment Operating cost EUR/hr 10 50 250 Cost saving - EUR/kg wire used Downtime 0.09 0.43 2.15 Weld quality 0.20 1.00 2,00 Equipment wear parts 0.05 0.10 0.20 Total EUR/kg wire 0.34 1.53 4.35 Total EUR for 250 kg MP 85 383 1088 Total EUR for 475 kg MP 162 727 2066 Save on rejects. Save on wear and spare parts. Straight wire delivery results in well-positioned welds and fewer rejects. A survey by a major Western European automotive producer revealed that savings on weld rejects and cleaning alone was almost five times that of savings on downtime with Marathon Pac. This was based on each workstation costing 50 euro/hour and corresponding to two euro/kg welding wire used. Another major European car company reported 90% cost savings on feeding system wear and spare parts after changing from spools to Marathon Pac. This was as a direct result of improved wire straightness and the elimination of weight related wear associated with revolving spools. Not only did the liners and tips last longer, but also the rollers and motors. With typical costs for spare and wear parts running at 200 to 400 Euro/year for each two tonnes of wire consumed, that means savings of between 0.10 and 0.20 Euro/kg wire.

Marathon Pac TM easier handling, installation and disposal. Transport of Marathon Pac by overhead gantry Handling Marathon Pac is designed for fast, efficient handling and ease of eventual recycling. Delivered on pallets containing four standard Marathon Pacs, or two Jumbo Marathon Pacs, the protective foil around each pallet is quickly removed. Compare that with traditional 18 kg spools which first have to be individually unwrapped - box by box. Marathon Pac is easily transported using a lift truck or a standard overhead gantry and the certified yoke that fits easily into built-in lifting straps. Additionally, there is a special trolley accessory to allow final positioning close to each welding station. Installation Once at the workstation, installation is simple and fast. For the Standard and Mini versions, you just snap the wire conduit to the quick-fit connector in the centre of the re-usable wire conduit lid or, for the Jumbo version, to the re-usable cone. Disposal Once empty, simply remove the lifting straps from the octagonal drum and fold it completely flat for easy and space saving storage until collection. Because each drum is made from 100% high quality, double-skinned recyclable cardboard, many users gain a return fee from their paper recycler. Compared to all the complex logistics involved in storing and returning spent spools and jumbo coils, it s easy to see how the savings continue to mount up. Remember also that Marathon Pac protects your welding wire from contamination and requires no potentially troublesome de-coiling equipment. Installation is simple and fast as shown here for Mini Marathon Pac. The wire conduit is connected to quick connectors on the wire conduit lid attachment (shown as a cross above) and on the wire feeder. Marathon Pac is easily disposed using environmentally-friendly recycling

Marathon Pac - a complete family. The Marathon Pac family. From left to right: Endless Marathon Pac, Mini Marathon Pac, Standard Marathon Pac and Jumbo Marathon Pac. ESAB Marathon Pac is the most advanced bulk wire packaging system available to fabricators. The complete Marathon Pac family consists of: Standard Marathon Pac Jumbo Marathon Pac Mini Marathon Pac Endless Marathon Pac Mini Marathon Pac is the newest addition and the perfect answer for fabricators with moderate usage of stainless steel wires, who wish to minimize the capital tied-up in a standard sized drum, without losing the benefits of low downtime and productivity. Endless Marathon Pac does exactly what it says, providing total efficiency with no stops for changeover at all. Well before the Marathon Pac finishes, the wire from a second Marathon Pac is joined to the first using a special portable butt welding device. The clever changeover mechanism then automatically transfers the feed from the first to the second drum while the robot continues to weld faultlessly. Endless Marathon Pac is ideal for in-line manufacturing and multi-robot stations. A more detailed brochure and description is available directly from ESAB or through your local ESAB distributor. The Marathon Pac TM family wire grades and filling content. Standard Jumbo Mini Endless Marathon Pac Marathon Pac Marathon Pac Marathon Pac W x H 513 x 830 mm 595 x 935 mm 513 x 500 mm 2 x standard or jumbo Non- and low-alloyed steel Solid wires 250 kg 475 kg 2 x 250 kg (Ø 0.8 mm: 200 kg) (min Ø 1.0 mm) 2 x 475 kg Cored wires Depending on type SAW wires Ø 1.6 mm: 475 kg Ø 2.0 mm: 450 kg Stainless steel Solid wires 250 kg 475 kg 100 kg 2 x 250 kg (Ø 0.8 mm: 200 kg) (min Ø 1.0 mm) 2 x 475 kg Cored wires Depending on type Aluminium Solid wires 141 kg Copper-based MIG-brazing wires 200 kg

Marathon Pac TM accessories. Marathon Pacs are made of strong corrugated board with a moisture barrier. Sizes are valid for the drum only. Add 135 mm for the trolley and 355 mm for the plastic hood of the Jumbo Marathon Pac. Trolley Lifting yoke Wire conduit lid attachment Spool type 93 Marathon Pac W x H= 513 x 830mm. Spool type 95 Mini Marathon Pac W x H= 513 x 500mm. Spool type 94 Jumbo Marathon Pac W x H= 595 x 935mm. Item No Product Spool type* 93 94 95 Marathon Pac Jumbo Pac Mini Marathon Pac F102365-880 Trolley X X Conduit to wire feeder connector F103900-880 Trolley X F102607-880 Lifting yoke yellow X X F102537-880 Lifting yoke red X F102433-880 Wire conduit lid attachment (cross) X X F102440-880 Wire conduit connector X X X F102442-880 Quick connector plastic hood X F102437-886 Wire conduit L=0.6 m X X X F102437-881 Wire conduit L=1.8 m X X X F102437-882 Wire conduit L=3.0 m X X X F102437-883 Wire conduit L=4.5 m X X X F102437-884 Wire conduit L=8.0 m X X X F102437-885 Wire conduit L=12 m** X X X F103901-001 Plastic hood X F102540-001 Plastic hood flat (option for standard and mini Marathon Pac) ( X ) ( X ) Quick connector plastic hood Wire conduit * Endless Marathon Pac and accessories are featured in a separate brochure available from ESAB. ** Other lengths available on request. Plastic hood

Marathon Pac TM a winner with General Motors. ESAB and General Motors discussed process support for optimising weld quality and productivity. Following initial tests, the investigation team starts work on welding the triangular cross members of the front axle suspension system of the successful Opel Zafira. For this trial they use OK Tubrod 14.13 metal cored wire delivered from an ESAB Marathon Pac. Impressed by Marathon Pac s performance, GME decided to conduct a comparative investigation into all other wire spooling and packing systems currently available. Price difference of various bulk wire systems when compared to the 475 kg ESAB Marathon Pac. Source: General Motors study. Cost increase Over the ensuing months various delivery systems 300 kg drums, 250 kg spiders, carton bulk drums and 250kg and 475kg Marathon Pacs were tested within the highly demanding conditions of a three shift production cycle. Marathon Pac, with its consistent quality, efficiency and environmental friendliness, backed by professional process support from ESAB, outperformed every other system on test. As a result, ESAB Marathon Pac is now specified for use in all GME factories. In summary After thorough testing and investigation, Marathon Pac is the leading system used in GME s OPEL, Vauxhall and SAAB production facilities. Depending on the application, Marathon Pac delivers unalloyed wires such as OK Autrod 12.51 for welding applications, copper based wires such as OK Autrod 19.30 for MIG brazing or OK Autrod 347Si for high alloyed material. Generally, the standard 250kg Marathon Pac is used, because most of the robot cells are not accessible to the 475kg Jumbo version.

World leader in welding and cutting technology and systems. ESAB operates at the forefront of welding and cutting technology. Over & Safety Management Systems across all our global manufacturing facilities. one hundred years of continuous T.M.C. Cadelbosco Sopra, Italy, supplies components to well known crane fabricators in Europe, including their sister company Basket. T.M.C. operates four robotic MAG welding stations that use 250kg Marathon Pacs containing AristoRod 12.50 and 13.29 for trouble-free feeding, less spatter and strongly reduced maintenance of the feeding system. improvement in products and processes enables us to meet the challenges of technological advance in every sector in which ESAB operates. Quality and environment standards Quality, the environment and safety are three key areas of focus. ESAB is one of few international companies to have achieved the ISO 14001 and OHSAS 18001 standards in Environmental, Health At ESAB, quality is an ongoing process that is at the heart of all our production processes and facilities worldwide. Multinational manufacturing, local representation and an international network of independent distributors brings the benefits of ESAB quality and unrivalled expertise in materials and processes within reach of all our customers, wherever they are located. ESAB Sales and Support Offices worldwide * Includes manufacturing facilities of ESAB North America. A wholly owned subsidiary of Anderson Group Inc. ESAB AB Box 8004, SE-402 77 Göteborg, Sweden. Phone: +46 31 50 90 00. Fax: +46 31 50 93 90. E-mail: info@esab.se www.esab.com Global solutions for local customers - everywhere. Reg. No: XA00098420 07 / 2008. Printed in the Netherlands.