Interbilt Gains Improved Gouging Results with Hypertherm Powermax

Company Overview

Interbilt Truck Repairs CC, founded in 1999, operates from Bapsfontein with two modern, fully equipped facilities. The company specializes in commercial vehicle recovery, towing, and repairs, and has built a strong reputation for high-quality vehicle customization. Interbilt’s competitive edge comes from its skilled team, deep technical expertise, and commitment to precision. As the company continues to expand its footprint in South Africa and across the continent, it actively seeks technologies to differentiate its services and strengthen its position in the commercial vehicle repair industry.

Challenges: traditional cutting torches generate excessive heat and warp steel

When a truck or trailer is out of service, customers face immediate operational and financial setbacks. According to Johan Lemmer, trailer workshop manager at Interbilt, a large portion of their work involves accident-damaged vehicles, many of which are tied to insurance claims. Speed and accuracy in steel repair are essential because delays directly affect clients’ businesses.

Traditional cutting torches, however, created significant obstacles. They generated excessive heat, which often caused steel components—especially chassis sections—to warp. Even slight distortion could compromise structural integrity, leading to additional repairs and extended downtime.

Michael Smit, one of Interbilt’s bodybuilders, adds that achieving clean, accurate cuts with torches was difficult and time-consuming. Gouging, a critical step when removing damaged chassis sections before welding, was particularly challenging. The torch-based process lacked precision, making it hard to remove only the weld without damaging the surrounding material. “Whatever you take out, you want to be able to use again,” Smit explains. Plasma technology offered a faster, cleaner, and more controlled alternative.

Lemmer notes that advancements in plasma cutting have made the work significantly more manageable and recommends the approach to others seeking a reliable, straightforward method for cutting steel.

Solution: Hypertherm Powermax reduces delays by providing a consistent repair process

Interbilt’s transition to Hypertherm began with the introduction of a CNC plasma machine, which immediately improved cutting accuracy. Building on that success, the company added a Powermax105 SYNC^® plasma cutter about a year ago. One of their recurring tasks—cutting out chassis cross members—highlighted the limitations of traditional torches. Excessive heat made precision difficult, and achieving the required accuracy demanded extra time and effort.

“With the torches, it was extremely difficult to get the cuts we needed. Hypertherm plasma cutters offer different tips that make the cutting process cleaner and far more manageable,” Lemmer says.

The impact was immediate. The improved workflow led Interbilt to add two additional Powermax units, with a fourth machine already planned. This steady expansion reflects how plasma cutting has streamlined daily operations and improved consistency in repairs. Smit also noted that, previously, changing torch tips was slow and required handling the tool directly. Now he can carry the necessary plasma cartridges and switch methods within minutes.

Because plasma cutters generate significantly less heat, the risk of warping is reduced, which is critical when working on sensitive structural components. The cleaner, more accurate cuts also improve welding preparation, reducing the time spent on grinding, adjustments, and rework. “Plasma cutting makes welding preparation quicker and easier. The overall repair process has become more predictable and efficient,” said Lemmer.

By adopting Hypertherm Powermax systems, Interbilt has strengthened its ability to manage workload, reduce customer downtime, and deliver consistently high-quality repairs.