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In the fight against the corona pandemic: Rösler Oberflächentechnik GmbH vaccinates workforce

Incidence rates are falling, the number of first and second vaccinations is increasing daily, yet many people in Germany still do not have sufficient protection against COVID-19 disease. Rösler now offers its employees an additional vaccination service. Rösler Oberflächentechnik GmbH does everything in its power to protect the health of its employees and makes it possible for its workforce to be vaccinated accordingly. In this context, almost 70 vaccinations were carried out on 14.06.2021, on a vaccination line specially set up at the Untermerzbach plant. "With the introduction of the Corona vaccination service, we as the Rösler company would like to offer our employees the opportunity to protect themselves from COVID-19 disease in the best possible way. This is a voluntary offer of the company health management that we implement in close cooperation with various doctors from the region. In addition to the local vaccination centers and general practitioners, we would like to make an active contribution to combating the Corona pandemic," emphasizes Stephan Rösler, President & CEO of Rösler Oberflächentechnik GmbH. Vaccine procurement proves difficult Despite a high level of commitment to procurement, the availability of the vaccine is causing difficulties, as demand far outstrips supply. Nevertheless, about 70 vaccine doses from the manufacturers Johnson & Johnson and Biontec could be procured and vaccinated. When distributing the vaccine, care is taken to give priority to those employees who do not have or have not had the opportunity to work in a home office. "Hopefully, when sufficient additional vaccine is available soon, we will be able to pass on even more vaccination offers to our workforce," adds Stephan Rösler. Extensive measures to combat COVID-19 The additional vaccination offer represents another important building block in the fight against the Corona pandemic. In addition, Rösler Oberflächentechnik GmbH continues to rely on extensive infection control measures and a comprehensive testing strategy. For this purpose, the company has developed a Corona concept, which is regularly adapted to current conditions. This includes compliance with the hygienic rules, regular testing, consistent implementation of the mask requirement and, wherever possible, mobile working from home.

Shot blasting, mass finishing and cleaning solutions, including consumables, from one single source

The services offered by the B+S Metallbearbeitung GmbH include all kinds of mass finishing operations like deburring, polishing, etc., as well as shot blasting, part cleaning and packaging. The company handles a broad range of work pieces with different shapes, made from different materials, requiring different finishes and coming from all kinds of industries. To ensure continued excellent quality and on-time deliveries in a cost-effective manner this service company is counting on well-trained employees and utilizes modern equipment and consumables from Rösler. The beginning of the B+S Metallbearbeitung GmbH dates back to the year 1959. The company, founded by Herbert Bickel, specialized early on in jobshop services in the field of mechanical surface treatment, such as mass finishing. In 1991 Mustafa Sahin became an employee of the B+S Metallbearbeitung GmbH located in Murr in Southern Germany. Since 2004 he held a 50% share in the company. When the founder decided to withdraw from the business in 2007 for health reasons, Mustafa Sahin became the general manager. He recognized quickly that in order to remain competitive and run the business successfully in the future, the outdated equipment had to be replaced with modern machinery. In addition, to strengthen the company’s competitive position in the market he decided to expand the service portfolio with additional finishing operations. An important aspect of this expansion strategy was to process the customer’s work pieces safely and consistently and to use high-quality equipment that could be operated round-the-clock. The best equipment technology for each mass finishing application The general manager remembers: „In a first step I talked with different suppliers of mass finishing equipment. Among them was also a Rösler employee. I was impressed by the broad Rösler equipment range and the excellent engineering of the high-performance machines, which can be utilized for all kinds of finishing tasks. Another important consideration was that Rösler produces all its mass finishing consumables in-house. This means that equipment, media and compound can be perfectly adapted to our requirements and that I can resort anytime to the experience and knowhow of the Rösler test lab. Above all, the relationship with the colleagues from Rösler is excellent.” In 2008 Mustafa Sahin decided to purchase a linear, continuous flow mass finishing vibrator, model R 425/6600 DA, that was technically adapted to the company’s requirements. In subsequent years the company purchased two additional continuous flow machines, 14 rotary vibrators and three centrifugal disk finishing machines, all from the equipment manufacturer in Untermerzbach. Service portfolio expanded by shot blasting and work piece cleaning Irrespective of the first negative effects of the financial crisis, in 2008 the entrepreneur invested in a shot blast machine to expand his service package. In this case Mr. Sahin decided to also purchase Rösler equipment. „I assumed that the quality of the shot blast equipment was comparable to the excellent quality of the mass finishing machinery. Through intensive consultations and the deep knowledge about shot blasting we could gain through our discussions with the Rösler experts, we determined that a continuous flow shot blast machine was the right product for us,” reports Mustafa Sahin. A major characteristic of the shot blasting process is that the equipment is subject to considerable wear. Therefore, a good technical service with short turnaround times were key factors in the decision for Rösler. „As a job shop we cannot afford long wait times for a service engineer and spare parts,” adds the general manager. Through the continuous expansion of its shot blasting job shop services, in the meantime B+S Metallbearbeitung has purchased six additional shot blast machines. The general manager continues: „Generally, shot blast equipment is subject to significant wear. Therefore, depending on how intensively they are used, we are selling our shot blast machines after 3 to 5 years as used equipment. This allows us to always be technologically up-to-date and to offer our customers the best possible results at competitive prices. With the work piece cleanliness requirements becoming more demanding, the company took advantage of another opportunity to expand its service portfolio. Mustafa Sahin reports: „In numerous conversations with our customers we learnt that many companies wanted to outsource the cleaning of their work pieces and that they were looking for a reliable job shop for this service. We found that work piece cleaning was an excellent opportunity to expand our surface treatment activities.” After comprehensive research and a thorough market analysis the customer chose a water based cleaning system from Rösler. The work piece cleaning operations are taking place in conjunction with mass finishing, shot blasting, a 100% quality control and/or packaging. But the cleaning services are also offered separately. In the meantime, work piece cleaning has become a core competency of the company and will be further expanded. In this respect the general manager is looking for a cooperation with a laboratory specializing in cleanliness analytics that will assist him to prove that the cleanliness demands for certain cleaning jobs have been met. A market position that has been achieved by quality, flexibility and taking calculated risks With its philosophy to react to the individual customer requirements with excellent quality, a high cost efficiency and on-time deliveries B+S has successfully established itself in the market. In the meantime renowned companies from various industries, such as car manufacturers and automotive suppliers, machinery building companies, furniture manufacturers, medical engineering companies, as well as foundries and stamping companies are relying on the services offered by the jobshop. The company handles work pieces made from aluminum, steel, stainless steel, magnesium, copper, brass and plastic components. The decision to utilize modern finishing technologies, high-quality equipment and consumables and the courage to invest during difficult times are certainly one reason for the success of B+S. Mustafa Sahin concludes: „Our success in the field of mechanical surface treatment depends on the right equipment, the best consumables and knowledgeable partners who can inform us about the latest developments and provide a comprehensive knowledge transfer. We get all this from a single source, namely Rösler.

Centrifuge Technology, Part 4 – Pre-Conditions and Consumables Enhance Process Efficiency

Establishing and maintaining an effective and cost-efficient process water recycling system requires consideration of a few essential points. Without the proper compounds , additives, and monitoring, even a well-designed piece of centrifuge technology is bound to falter and, eventually, fail. Rosler has extensive experience in mass finishing , including designing and manufacturing equipment, fine-tuning processes, and supplying the right consumables for a variety of processes. With our knowledge, preconditions and consumables can be calibrated for maximum process efficiency. Special Recycling Compounds Mass finishing compounds fulfill numerous tasks such as degreasing/de-oiling work pieces, burnishing/brightening surfaces, and providing a temporary corrosion protection. Above all though, the primary task of the compounds is to keep the media and work pieces clean to achieve the desired finishing goals and keep the mass finishing process stable. Since compounds stay in the process water rather than being collected and discharged with contaminants, compounds used in recycled process water must have special technical attributes. In addition to their standard properties these recycling compounds must: Have better dirt dispersing capabilities than single-use cleaners. Create very little foam. Be highly compatible with the process water cleaners. Prevent bacteria growth in the system. Cleaners designed for single-use processes would not provide adequate cleaning of the water or the work pieces and may allow contaminants to reenter the equipment with recycled water, potentially damaging the machine. Process Water Cleaning Additives Whether in liquid or powder form, cleaning additives known as flocculants must be added to the process water to support the cleaning effect of the centrifuge. Certain process water cleaners combine tiny solid fines into larger and heavier particles, making it easier for the centrifuge to separate them from the liquid. Other cleaners pick up tiny droplets of emulsified oil and combine them with the solids into larger flocs, which are then separated from the liquid in the centrifuge. Finding Balance Rosler Water Recirculation System When work pieces enter the mass finishing machine, they carry a variety of contaminants as well as some sort of surface material that is in need of removal or texturing. During the finishing process, effluent or used process water is transferred to an effluent holding tank where it awaits cleaning. The centrifuge processes “dirty” process water using the centrifugal force of more than 2,000 G to separate clean, reusable water and compounds from sludge for discharge. The clean water is stored in a clean water tank ready to be re-used in the finishing process. Automatic and semi-automatic systems monitor the composition of the cleaned water to add additional water and compounds as needed. The process water is then sent back to the finishing machine for reuse. Consumable Expertise In conjunction with centrifuge technology, Rosler offers a complete range of suitable recycling compounds and process water cleaners. For best results, the compound concentration in process water must be approximately 2% although certain applications may have to be somewhat higher. Mass finishing processes utilizing process water recycling with centrifuges require special dosing systems to monitor and maintain compound and process water cleaner levels. They also require a water top‐up system to replace process water lost by carry‐out and evaporation. Automated and semi-automated options are available. The Rosler Way Whether ensuring that the precondition of recycled water is suitable for reuse or selecting the most effective cleaning consumables are used in and outside a centrifuge process, Rosler sticks to its motto of “Finding a better way…” Contact us to discuss your cleaning centrifuge challenges so we can get to work developing a solution. Previous posts in the Centrifuge Technology series include: Part 1 – “Water Cleaning Systems Replace Outdated Methods.” Part 2 – “Operational and Economic Benefits of Recycling Process Water.” Part 3 – “Mechanics and Limitations of Water Recycling.” Part 4 – “Pre-Conditions and Consumables Enhance Process Efficiency.” Upcoming posts in the Centrifuge Technology series will include: Part 5 – “Potential Issues and Remedies for Water Recycling.” Sign up for enews alerts to be notified of new posts!

Optimized finishing process with a new, non-foaming plastic media

Better results, higher productivity and improved cost-efficiency In general, the optimization of mass finishing processes is mostly focused on the machinery. A finishing application at the job shop company Dörfler & Schmidt Präzisionsfinish has shown that by simply using a different media, a significant process optimization can be achieved. By switching to a new, non-foaming plastic media from Rösler the customer achieved a higher process stability, higher productivity and an improved efficiency. Founded in 1998, the Dörfler & Schmidt Präzisionsfinish GmbH offers a wide range of surfaces, such as deburring, edge radiusing surface smoothing, polishing, creating mat and structured finishes, descaling and cleaning. For these services the company is utilizing mass finishing, shot blasting and brush deburring equipment. The company is treating work pieces made from metal, plastic, ceramic, glass and wood. The work piece dimensions can range from a few mm up to 60 centimeters. The customers of this family-owned company, located in Kammerstein in the state of Bavaria, come from all kinds of industries like automotive, machinery building, electronics, medical engineering, jewelry and a variety of consumer goods manufacturers. A company utilizing different types of mass finishing technologies The highly heterogeneous clientele of Dörfler & Schmidt requires all kinds of surface finishing solutions. Felix Dörfler, executive assistant, comments: „We have to deal mostly with requests for deburring and edge radiusing. For example, on tools like milling tools and cutting inserts we have to create a precise edge radius. Other work pieces, such as bearing rings must have precisely defined surface roughness readings after the finishing operation. On the other hand, jewelry and accessories must have an optically pleasing finish.” To be able to offer its customers the technically and economically best solutions, the company operates 33 different machines that can handle a broad range of different mass finishing technologies. Felix Dörfler continues: „To handle the various work piece materials we employ different process water cleaning and recycling systems. For this purpose we are utilizing five centrifuges, which like the overwhelming majority of our mass finishing equipment, were supplied by Rösler.” When it comes to consumables, Dörfler & Schmidt is also primarily using Rösler products. “The consistently high quality of the Rösler media and compounds and the excellent support in the field of process development and optimization by the Customer Experience Center are just a few reasons that right from the beginning we relied on solutions from Rösler”, concludes the executive assistant. New plastic media suppresses foam that interferes with the finishing process Mass finishing processes with plastic media pose frequently a problem with foam, even when so-called foam-reducing media are used. The extent of the foaming issue depends to a large extent on the hardness of the process water used in the finishing process. For resolving this problem, frequently special additives are utilized. This was also the case with an application at Dörfler & Schmidt. Felix Dörfler explains: „For the deburring and edge radiusing of 40 mm long stainless steel wire segments we need an excellent grinding performance with a high metal removal rate. However, the foaming during the finishing process created a buffer between the work pieces and the media, which reduced the grinding effect. Therefore, the desired finishing results could no longer be achieved within the prescribed cycle time”. But the unwanted prolongation of the cycle time was not the only problem. The separation of the finished work pieces from the media was also affected and did no longer function properly. The foaming issue was even carried over to the process water cleaning system, where foam was seeping out of the centrifuges. This soiled the system itself and the immediate environment. When the responsible Rösler sales agent was informed about this problem in July 2020, he proposed the use of a non-foaming plastic media that had recently been developed by the Rösler process engineers. Since the beginning of 2021, Rösler offers all standard plastic media types also in the non-foaming “N” version, which regarding the shape, size and grinding performance is identical with the old product. Since the use of the new media required no modification of the finishing process at Dörfler & Schmidt, the company replaced the old media with the new, non-foaming version. Higher process stability, improved efficiency and higher sustainability Dörfler & Schmidt is one of a selected group of companies who have tested the new media. The company has now been working with the non-foaming version for about nine months. The first test phase demonstrated impressively that the required processing results are safely achieved within the prescribed cycle time and that the separation phase also works well. The media switch to the non-foaming version has also greatly simplified the monitoring of the finishing process. Since the time for unwanted re-work could be completely eliminated, the overall cost-efficiency was significantly improved. Another benefit of the new media is that the usable life of the process water could be extended. This helped reduce the consumption of additives, a big plus for the environment and for achieving sustainability. Felix Dörfler summarizes: „We have been using the non-foaming media in two machines. And we have found that the grinding performance and the wear rate are absolutely identical with the standard version. The new media helped us to make our processes more cost-efficient without affecting the quality of the finishing results. For this reason, we will switch more plastic media types to the non-foaming version”.

Wet Blasting Technology, Part 5 – PureFinish® Offers Food-Grade Excellence

Within the food, chemical, and pharmaceutical industries , hygiene is a top priority. For safety and quality assurance, the occurrence of contamination through bacteria, proteins, or other elements must be prevented. Process plants require a defined, homogeneous, and reproducible surface for all parts that come in contact with food, beverages, chemicals, and pharmaceutical products. Rosler delivers full compliance cleaning for stainless steel surfaces with PureFinish® , a unique wet blasting process. What is PureFinish®? Rosler developed this proprietary blasting process to deep-clean stainless steel components. Media specifically designed by Rosler for this environmentally friendly process remains suspended in water and is propelled onto the work piece surface with velocity. In the example shown, oxidation from welding on stainless steel components is completely removed after treatment with PureFinish®. Optimum Surface Finish The key advantage of PureFinish® is the optimum surface finish it achieves. The process creates a highly homogeneous surface profile with roughness readings of Ra = 0.25-0.60 µm. Not too rough and not too smooth, this profile is ideal for preventing bacteria from growing on and adhering to the surface. As shown below, bacteria growth only occurs if a surface is too rough or too smooth. Surface characteristics and goals This optimum surface profile allows easy removal of dirt and bacteria and, therefore, facilitates cleaning and sterilizing the surface. Additional advantages include: PureFinish® meets all hygienic requirements of the EHEDG (European Hygienic Engineering & Design Group) . Much lower ratings on the Soil Retention Index (SRI) compared to stainless steel surfaces cleaned with other cleaning methods. Considerably fewer contaminants left on the surface. The purely mechanical process does not require any hazardous pickling chemicals. PureFinish® creates a peening effect on the surface that makes the component more durable and prevents premature corrosion due to stress cracking. A welded work piece before and after PureFinish® treatment The Rosler Way With more than 80 years of experience in surface finishing, the Rosler team has expertise in the wet blasting field. This experience allowed us to create PureFinish® and its unique capabilities. To demonstrate our capabilities, we offer FREE sample processing in our global test centers . Contact us to discuss your wet blasting goals and challenges. The complete Wet Blasting Technology Series includes: Part 1 – “Wet Blasting Gently Delivers Dramatic Finishing Results.” Part 2 – “Comparing Attributes, Advantages to Dry Blasting.” Part 3 – “Technical Features, Slurry Control Achieve Precise Finishing.” Part 4 – “Typical Wet Blasting Applications.” Part 5 – “PureFinish® Offers Food-Grade Excellence.” Sign up for enews alerts to be notified of all Rosler blog posts!

Rösler Anti-Dust: An additive for the dust absorption in drying processes with drying media

Over 90 percent of all mass finishing applications are wet processes, where the finished work pieces must subsequently be dried. For this purpose, driers, filled with organic granules such as maize-cellulose product, are frequently utilized. Unfortunately, these organic materials are producing dust. The Rösler Anti-Dust additive reduces the dust formation significantly. Anti-Dust is an easily dispensable liquid additive that can be used for drying of all kinds of metallic and plastic work pieces in conjunction with drying media. Already small amounts of Anti-Dust additive are effective over a period of several days and can be quickly replenished as needed. Without affecting the drying performance, it ensures less residual dust on the work pieces, in the environment and in the dryer. Environmental compatibility also played an important role in the development of this product. Anti-Dust consists of plant based materials and, in addition, is as safe as food. The benefits of Anti-Dust at a glance: Less residual dust in the dryer and the environment Spot-free drying of the work pieces No negative effect on the drying performance Made from ecologically sustainable materials and as safe as food Liquid additive that allows easy dosing

Preservation Lines Deliver Multi-Step Surface Finishing in a Single Machine

Complete systems for blast cleaning and placing a protective coating, preservation lines are extremely useful on plates and profiles that require multiple treatments. For example, structural steel components are commonly processed by preservation lines because they are prone to rust quickly and fail with potentially catastrophic consequences if not covered with a suitable, protective coating. Rosler has extensive experience preparing structural steel components for use in construction , shipbuilding , and the production of all kinds of heavy-duty vehicles, trucks, railway vehicles, agricultural implements, or construction equipment. We understand the importance of applying proper surface finishing processes to these components for safety and longevity. Offering shot blasting , painting, and more in a single source, preservation lines are a great option for a variety of industries , especially those utilizing structural steel components including steel plates, beams, round bar stock, and tubes. Components & Functions Preservation lines incorporate material handling, blast cleaning, and protective coating and/or painting in a single process. While customized options and accessories can be added in, preservation lines typically include six key components. Rosler's preservation lines are customizable to your needs. This diagram shows common components included. Material Handling (1) These integrated transport systems utilize roller conveyors, cross transport units, and other methods to move sometimes large and heavy work pieces before and after processing within the preservation line. Blow-Off Units (2) Designed to remove water, dust, leaves, and other loose contaminants before blasting, these stations help ensure components are clean enough for the subsequent finishing process. They may also be combined with brush-off units. Rosler blow-off unit Pre-Heaters (3) Used in front of the shot blast machine to melt snow and ice, pre-heaters ensure that the work pieces do not carry any moisture into the shot blast machine. The pre-heater also serves a dual function, bringing work pieces to the optimum temperature of about 100° F (40° C) for the subsequent cleaning coating process. Shot Blast Machines (4) Using propelled media , this section of the machine removes rust and scale from the work piece and creates the correct pre-paint surface profile/roughness. Work pieces move through the shot blasting area on roller conveyors . Paint / Coating System (5) Automatic, high-speed, gantry paint systems apply paint and protective coatings in this step of the process. The paint cabin also contains any overspray and paint fumes through mist filtering, roller brush systems, and the air filtration systems. Paint Dryers (6) Post treatment of components within the drying station ensure that paint and coatings applied in the paint cabin are appropriately dried and cured for improved adhesion and life expectancy. These dryers frequently utilize excess heat from the pre-heater to minimize power use by up to 10 kW. Rosler paint dryer The Rosler Way Rosler has the experience and expertise to solve your surface finishing challenges by developing a preservation line to meet your needs. We partner with you to find a better way, the best machine, and the best finishing results. Contact Rosler today to discuss your unique challenges.

Optimized finishing process at Gardena increases productivity and lowers costs

Improved productivity, increased production capacity, better quality and lower costs. These were the demands of a leading garden tool manufacturer, when he invested in a new mass finishing system for deburring and polishing of garden shear knives. Rösler met this challenge with a tailormade Keramo-Finish process that is run in a double batch centrifugal disk finishing machine FKS 35.1 A2-So with fully automatic work piece handling. In a two-stage process the stamped and laser-cut knives are deburred and polished in the FKS finishing machine. Subsequently they are dried in an energy-efficient rotary dryer and prepared for the next manufacturing step. For more than 60 years, Gardena, a brand of the Husqvarna Group, has been offering everything ardent gardeners need. The broad product range includes innovative systems for irrigation, lawn, tree and shrub care, as well as soil cultivation. Gardena products are used in more than 80 countries all around the world. A transformation to ultra-modern equipment and process technologies To ensure easy and simple handling, produce excellent cutting performance and guarantee a long service life, the shear components are produced with state-of-the-art manufacturing technologies. Important steps are the stamping or laser cutting of the upper and lower knifes followed by a deburring and polishing process in mass finishing equipment. Previously the lower knifes required two separate finishing operations, one in a rotary vibrator and one in a centrifugal disk finishing machine. To combine these two operations into one and adapt them to the latest manufacturing requirements, the existing mass finishing equipment, used over many years, was replaced. Gardena chose a finishing solution from the Rösler Oberflächentechnik GmbH, who had already supplied the machinery used to date. By investing in new equipment the customer was looking for a comprehensive optimization of the finishing process that improved not only the productivity and offered a higher capacity but also resulted in lower costs. A finishing system that produces shorter cycle times and improved operational efficiency Based on the surface finishes of the steel knifes that are required for the next manufacturing steps, the Rösler process engineers ran a series of processing trials in their test lab with various processing media and different process parameters. The best results were achieved with a Keramo-Finish process in a centrifugal disk finishing machine. This includes the use of a ceramic media with minimal abrasive characteristics in combination with a grinding and polishing paste and a cleaning compound with a distinct brightening effect. The new process allows the deburring and polishing of all knifes in one single machine. The rotary vibrator was no longer required, and the work piece handling was simplified. Moreover, depending on the work piece type, the new Keramo-Finish process reduces the processing times by 25 % to over 100 % and also allows bigger work piece batches. This helped to reduce the operational costs by around 10 % with, at the same time, greatly improved finishing results. Fully automatic processing in a double batch system The new double batch centrifugal disk finishing machine was perfectly integrated into the manufacturing flow at Gardena. Work piece specific processing programs stored in the PLC controller allow the targeted finishing of the various knife types. After stamping, respectively, laser cutting the work pieces are collected in perforated metal bins. The operator utilizes a swing crane to dump the raw knife components into a loading device that transfers them into a vibratory feed hopper. After the respective finishing program has been manually selected, the hopper automatically feeds a work piece batch into the work bowl for processing. After the preset finishing time the work bowl gently dumps the mix of finished work pieces and media onto a vibratory hopper from where the mix is transferred to a vibratory separation unit. There, with a precisely sized hole screen, the media and finished work pieces are separated from each other. At the same time, a special undersize media screen is discharging media that is no longer suitable for the finishing process. This guarantees a continuous high process stability. While the media is returned into the work bowl, the finished knife blanks are transferred to the drying station filled with a maize-cellulose product. The rotary dryer RT 550 Euro-DH is equipped with an innovative new heating system that guarantees not only fast, reliable and spot-free drying of the work pieces but also produces energy savings of up to 40 % compared to conventional rotary dryers. After completion of the drying cycle the knifes are transferred to another vibratory hopper that loads them into waiting small transport carriers made from plastic. A fully automatic Z 1000 centrifuge is cleaning the process water and recycling it back to the mass finishing system for re-use in the finishing process. This helps save valuable resources. The drastically reduced water consumption, along with the innovative finishing solution and well-planned process controls ensure a sustainable and efficient operation of the new mass finishing system.

Centrifuge Technology, Part 3 – Mechanics and Limitations of Water Recycling

Combining the direction of rotation and centrifugal force, Rosler’s centrifuge technology takes advantage of the weight difference between the liquid phase and the solids in the process water to separate “dirty” solid particles from clean, reusable process water. The effectiveness of this technology lies in the centrifugal force that is created. For example, a modern fighter jet develops a G-force of about 10-15 while a high-speed centrifuge drum generates a force of more than 2,000 G. The physics of centrifuge technology combined with mass finishing equipment creates efficient and ecologically sound manufacturing processes, albeit with some key limitations. Collection by Force The solids, primarily consisting of media and, to a lesser degree, of metal fines from the work pieces, found within “dirty” process water are heavier than the water itself. As the drum spins, heavier solids are deposited on the drum wall in the form of sludge, whereas the lighter-weight liquid remains on the inside of the drum. With the addition of special cleaning additives known as flocculants, even oil carried into the mass finishing process can be removed from the process water. As shown in the diagram below, dirty process water is pumped down into the centrifuge drum (1) which is then accelerated by the applied centrifugal force. While the cleaned water is picked up by a so-called collection tube (2) for reuse, the sludge (3) is collected and periodically removed from the drum by mechanical or manual means. Limits of Cleaning The presence of solids in the process water is a must. Centrifuge technology works best when the process water contains a certain amount of solids and there is a notable weight differential between the liquid phase and the solids. Through the addition of special water cleaners, centrifuges can also remove oil from mass finishing process water, provided, of course, that the oil content is not too high. There are a few exceptions in which certain applications produce no or only very few solids in the process water, making centrifugal cleaning difficult or impossible. This is the case with: Ball burnishing and pressure deburring when steel media is used instead of ceramic . Part-on-part finishing when no media is used at all. High-end polishing operations where residual solid particles in the recycled process water might negatively affect the polishing quality. While process water from these applications is not suitable for centrifugal cleaning and recycling, it must be cleaned with other cleaning methods prior to discharge. Disposal of the Depleted Process Water If properly maintained, process water can last for a long time, usually between 3 to 12 months. Once it becomes too contaminated for cleaning, it must be replaced with a new batch of fresh water and compound. Reasons for depletion include: An abundance of solid fines which are too small to be picked up by the centrifuge. Too much oil carried into the finishing process. A bacteria buildup due to poor maintenance. The build-up of salts in the water that affect the finishing process. In such cases, the depleted process water must be cleaned in a “floc & drop”, membrane, or evaporation system prior to disposal. Depending on the type and level of contamination in the “dirty” water, straight sewer discharge could be illegal, costly, and/or unsafe. The Rosler Way The experts on the Rosler team can help identify the best centrifuge technology for your unique process challenges and develop solutions accordingly. Contact Rosler today to learn how we can improve and enhance your mass finishing process. Previous posts in the Centrifuge Technology series include: Part 1 – “Water Cleaning Systems Replace Outdated Methods.” Part 2 – “Operational and Economic Benefits of Recycling Process Water.” Part 3 – “Mechanics and Limitations of Water Recycling.” Part 4 – “Pre-Conditions and Consumables Enhance Process Efficiency.” Upcoming posts in the Centrifuge Technology series will include: Part 5 – “Potential Issues and Remedies for Water Recycling.” Sign up for enews alerts to be notified of new posts!

New continuous flow wire mesh belt blast machine from Rösler runs more efficiently and saves valuable resources

Over the course of a project to improve overall productivity and to make the coating of WPC (wood plastic composite) profiles more eco-friendly, the Jürgen Schröder GmbH has invested in new machinery. Specifically, the company purchased a new wire mesh belt machine RDGE 600-L from Rösler. The Jürgen Schröder GmbH, founded in 1980, has established itself in the market as a painting job shop for wooden windows, sun rooms, planed components, all kinds of moldings, doors, etc. For painting wooden components the company, with many years of experience, is also utilizing ultra-modern coating technologies. Decisive factors for choosing the continuous flow wire mesh belt blast machine RDGE 600-L were the excellent quality, the machine design tailored to the company’s requirements and the professional support by the Rösler sales team. Strict requirements regarding performance and sustainability At the moment the WPC profiles, such as base boards or floor boards for decks, are extruded at the suppliers with the color requested by the customers already mixed into the molding compound. This causes frequent production stoppages and material losses at the extrusion lines, whenever a color change takes place. Therefore, it is not surprising that all involved parties wanted to eliminate these color changes by applying the desired color after the extrusion operation. A tailormade equipment concept thanks to the Rösler experts Pre-condition for the optimal adhesion of the applied paint is the best possible surface preparation of the material substrate. The experts from Rösler and the Jürgen Schröder GmbH worked closely together to develop a process that not only met but exceeded the customer’s expectations. Tests to find out how the coatings perform under the most severe weather conditions and mechanical load tests proved very quickly the positive results so that the project could be implemented on an industrial scale. Subsequently, Rösler developed a shot blast solution that is perfectly adapted to the specific work piece requirements and the capacity demands. The new system is also in full compliance with the existing and new logistical manufacturing conditions. By purchasing the continuous flow wire mesh belt blast machine RDGE 600-L the customer could also take advantage of this machine’s small footprint, its high cost efficiency, its ease of maintenance and excellent uptime. The RDGE is equipped with two extremely wear resistant and easy-to-maintain high performance turbines . These are throwing the blast media on the WPC work pieces passing through the machine at a closely controlled speed and impact energy. The effect is a perfectly structured, isotropic work piece surface. An integrated blow-off system is removing all residual blast media and other particles from the shot blasted work pieces. The particular work piece material required the installation of a dry dust collector with built-in explosion protection. Of course, the dust collector is in full compliance with all industrial safety regulations. The shot blast machine, tailored to the specific customer’s needs, met not only his requirements regarding performance, cost and energy efficiency and equipment uptime, but it also represents a significant contribution towards environmental compatibility. Björn Schröder, general manager of the company, summarizes his expectations for the new shot blast machine: „Sustainability and a policy that protects valuable resources have always had a special place in our corporate philosophy”. Against this backdrop it was only natural that the project was partially funded with a grant from the European fund for regional development. „We were impressed by the excellent equipment engineering and the professional advice of the Rösler people at our location and at Rösler’s test center. The integration of the shot blast machine into our existing manufacturing line could also be implemented without any flaws. We will contact Rösler for any future shot blast projects”, summarizes Björn Schröder, general manager of the Jürgen Schröder GmbH.