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Auch in Zeiten von Corona: Rösler ist stolz auf seine Jubilare

Die Rösler Oberflächentechnik GmbH dankt 48 langjährigen Mitarbeiterinnen und Mitarbeitern in diesen herausfordernden Zeiten für insgesamt 975 Jahre Treue und Loyalität – die Feierlichkeiten fanden im kleinen Rahmen unter strenger Einhaltung der Hygienevorschriften statt. Die feierliche Ehrung der Betriebszugehörigkeit und die Verabschiedung von Mitarbeitern in den Ruhestand hat bei Rösler eine lange Tradition. Angesichts der anhaltenden Corona-Pandemie musste die traditionell auf Kloster Banz stattfindende Feierlichkeit dieses Jahr leider abgesagt werden. Doch um die Wertschätzung gegenüber den Jubilaren zu zeigen, fanden die Ehrungen in Kleingruppen durch die entsprechenden Führungskräfte zu separaten kurzen Terminen unter Wahrung der erforderlichen Hygieneregeln statt. In diesem Zusammenhang dankten die Führungskräfte im Namen der Firma Rösler allen Mitarbeiterinnen und Mitarbeitern für die jahrzehntelange Treue und deren Engagement, insbesondere in so schwierigen und unsicheren Zeiten wie diesen. Die Rösler Oberflächentechnik GmbH gratuliert … zum 40-jährigen Betriebsjubiläum: im Werk Memmelsdorf: Bernadette Hertel, Frank Möller, Johann Wendler, Rüdiger Böhm sowie Karin Schaarschmidt aus dem Werk in Hausen. … zum 25-jährigen Betriebsjubiläum: Dirk Neupert, Ralf Müller, Jan Reinmann, Reiner Kirchner, Bernd Klett, Jürgen Geisler, Heiko Vogel, Georg Bornschlegel, Friedrich Steinepreis, Gerhard Wagner, Thomas Dillinger, Daniel Bätz, Uwe Michael, Bodo Helmert, Andreas Ereth, Denis Dorittke, Irene Walther, Uwe Lautensack, Thomas Dreßel, Gerhard Edelmann – alle tätig im Werk Memmelsdorf – sowie Alex Britner, Eduard Neimann und Heiko Traut im Werk Hausen. … zum 10-jährigen Betriebsjubiläum: im Werk Memmelsdorf: Jakob Koch, Florian Müller, Kathrin Bätz, Matthias Voigt, Leo Higgs, Andreas Schubert, Günter Elflein, Jürgen Buss, Ingo Staak, Sylvia Eichenberg, Michael Klemmt, Werner Vießmann, Igor Ratz, Daniel Jahn, Jessica Ebert, Sonja Tal, Daniel Schramm, Rainer Sauerbier, Alexander Jost und Björn Nesbor. Langfristiges Erfolgsdenken als Teil der Rösler DNA Stephan Rösler, Geschäftsführender Gesellschafter der Rösler Oberflächentechnik GmbH, bedankte sich darüber hinaus in einem schriftlichen Weihnachtsgruß bei allen Mitarbeiterinnen und Mitarbeitern für deren Einsatz und Loyalität. Trotz der momentan schwierigen wirtschaftlichen Situation, in welcher viele Unternehmen ihre Produktion und Neuinvestitionen deutlich zurückfahren und die Firma Rösler dadurch bedingt einen deutlichen Umsatzrückgang zum Vorjahr verzeichnen werde, ist es sein erklärtes Ziel, die Rösler Gruppe für eine langfristige, nachhaltige und erfolgreiche Zukunft aufzustellen. So wurden zuletzt zukunftsweisende Investitionen, wie z. B. in den Bereichen Compoundfertigung, Logistik, Keramikfertigung, mechanische Fertigung, Rösler Academy, Kunststoffschleifkörperfertigung sowie in ein neues Betriebsrestaurant oder in Photovoltaikanlagen, angestoßen. Auch im jüngsten Geschäftsfeld AM Solutions, welches sich mit den Herausforderungen des 3D-Drucks beschäftigt, konnte zuletzt ein prestigereiches Projekt mit dem renommierten Druckerhersteller HP erfolgreich umgesetzt werden. Er betonte zwar, dass man sicherlich keinen Einfluss auf alle Dinge habe, aber dass er und sein Führungsteam ihr Bestes getan hätten und auch weiterhin tun, um die Zukunft der Firma Rösler erfolgreich und nachhaltig zu gestalten.

Mass Finishing Media, Part 3 – Why Discharging Undersized Media, Maintaining Media Levels Are Crucial

Mass finishing processes are effective because the motion of media against work pieces transforms the surface of the work pieces. The deflashing , descaling , edge rounding , polishing/smoothing , cleaning/oil removal/degreasing , and/or grinding effects change the surface of the media itself along with the work pieces. As a result, media wears down over time, losing its shape, size, and effectiveness. Known as undersized media, this worn media must be discharged and replaced with fresh media to ensure proper processing and safety. Whether a process uses ceramic , plastic , or polishing and drying media , Rosler stresses the importance of monitoring media levels and the mix of new and worn media for precise and safe mass finishing results. Worn Media Reduces Process Effectiveness Over time, media wears and becomes smaller. This undersized media can throw a process completely out of balance in several ways, including: Media lodging in the work pieces which could cause safety issues later in the process. Clogging drains within the finishing machine and causing flooding. Failing to meet finishing standards. Increasing required finishing times. Poorly selected media shapes and sizes can lead to problems such as ineffective finishing and media lodging within the work pieces as shown. Timely and effective discharge of the undersized media and replacing it with new media is, therefore, critical for the stability of any mass finishing process. Discharge can be done continuously by building suitable undersize screens into the actual mass finishing machine or in the vibratory screening unit. To prevent media clogging, undersize screens themselves must also be monitored. If lodging or clogged drains occur over time, undersize screens with larger holes should be installed. Undersized media screens allow media that is too small to be effective any longer to fall through screen holes and remove it from the media mix. In rotary vibrators with internal separation, the undersized media discharge can sometimes be inefficient. Running the complete media charge through an external vibratory screening machine equipped with special undersize screens every few days provides effective removal of undersized media and helps maintain the optimal media mix. New Media Offsets Undersized Loss Removing undersized media must be offset by the addition of new media. Without timely replacement, the media level in the machine will become lower, which may drastically impact the finishing process in several ways. Decreases in the media-to-work piece ratio will cause nicking and scratching of the work pieces. A higher portion of smaller media in the machine will prevent the process water from getting drained from the machine resulting in dirty work pieces. In vibratory machines, the spiral movement of the media/work piece mix will collapse if the media level drops too low resulting in poorer finishing results and longer cycle times. The media level in this rotary vibrator is too low In all cases, the process will completely collapse within a few days—sometimes within a few hours! Depending on the machine and media type, new media should be added at regular intervals such as with every work piece batch, once every few hours, or once a day. Your media supplier should be able to help you with frequency based on test batches and careful monitoring. Equipment updates may also be available to automate media replacement such as the installation of a timer- or weight-controlled media replenishment system to help maintain the right media working mix. The Rosler Way As a supplier of mass finishing media and machines, Rosler has the expertise to both engineer unique applications and supply the consumables and advice necessary to keep them operating efficiently. Contact us to learn how we can solve your unique challenges and meet your ongoing needs. The complete Mass Finishing Media Series includes: Part 1 – “Don't Navigate the Complex Selection Process Alone.” Part 2 – “Tips for Measuring Media-to-Work Piece Ratio.” Part 3 – “Why Discharging Undersized Media, Maintaining Media Levels are Crucial.” Sign up for enews alerts to be notified of all Rosler blog posts!

New seminar program 2021 of Rösler Academy now available

"An investment in knowledge always pays the best interest" - even Benjamin Franklin knew that "lifelong learning" is the best prerequisite for professional success. Particularly in challenging times, qualified employees are an indispensable component. With the publication of our new seminar program for 2021, we are again pleased to be able to offer you numerous practice-oriented seminars. The wide-ranging offer covers the areas of mass finishing and shot blasting technology, additive manufacturing as well as lean management. In the seminar program you will find all relevant information on the individual dates as well as detailed descriptions of the contents, duration and prices. An overview of all seminars can be found here as well as the German-language seminar program as PDF for download . For our international customers we offer our seminars also in English-language, you can find the overview here as well as the new seminar program as PDF for download . Nutzen Sie die Möglichkeit und investieren Sie in eine zielgerichtete Schulung Ihrer Mitarbeiter*innen. For further information visit: www.rosler-academy.com

Radiusing of tooling components with the drag finishing technology

Radiusing of tooling components with the drag finishing technology To date the voestalpine Rotec GmbH, a global leader in the manufacture of precision steel pipes and tubes, has been using a manual process to place a radius on its stamping tools. Within the framework of its continuous process optimization program the company replaced this manual operation with an automated Rösler drag finishing system R 4/700 SF. With the single piece dry drag finishing process the usable life of the stamping tools can be at least doubled. For some tools the uptime can even be increased by a factor of ten. For this reason, the return on investment period (ROI) is well below two years. With eleven manufacturing locations in Europe, North-America and Asia the voestalpine Rotec is a globally operating company that is specialized in the manufacture, refinement and marketing of precision steel pipes and tubes. Since the company belongs to the internationally operating steel and technology corporation voestalpine, the customers have direct access to comprehensive knowhow ranging from steel liquification to the complete pipes and tubes. The development of innovative products and manufacturing technologies takes place in four divisions. Within the corporate structure the voestalpine Rotec, headquartered in Krieglach, Austria, belongs to the metal forming division. At this location the company manufactures primarily belt tensioning tubes for the automobile industry. The complex manufacturing equipment for making pipe and tube components is also designed and built at the same location. Hannes Winkler, assistant to the plant manager at voestalpine Rotec and responsible for process optimization, explains: „To be able to make our products at internationally competitive costs, our company is utilizing continuous improvement processes.” Cost reduction by increasing the usable life of tooling Even before wear became visible, stamping tools like arbors and die plates had to be replaced because of minor fracturing at the edges. Frequently the edges were reworked by hand. But this did seldom extend the usable life of the tools. With around 50 million manufactured components per year tooling supply was a significant cost factor. Therefore, it was not surprising that the process optimization specialist was looking for an automated, repeatable edge radiusing process for prolonging the service life of the tooling. Cost-efficient dry processing in a drag finisher Edge radiusing of the tools is an ideal application for the drag finishing technology. This unique mass finishing system allows the precise, targeted surface finishing of high-value, complex work pieces. Exactly defined process parameters guarantee absolutely repeatable finishing results. “From my previous occupation at a supplier of motor sport components I knew that Rösler Oberflächentechnik builds such equipment. That is why I contacted Rösler first. Of course, we also contacted other suppliers of mass finishing equipment and asked them to run processing trials for us”, continues Hannes Winkler. In the end the customer chose the R 4/700 SF system, because Rösler was the only supplier, who could offer a dry finishing process for the tools. Hannes Winkler adds: „The dry solution eliminated the process water cleaning system required with the wet processing solution. This reduced not only the capital expenditure but also resulted in lower operating costs. Of course, the quality and long service life as well as the high availability of the Rösler equipment also played an important role in our decision.” Automated finishing that is perfectly adapted to different tools At the heart of the compact, plug-and-play drag finisher is a carousel equipped with four rotary spindles, each spindle allowing the mounting of three work pieces. The carousel and the rotary spindles are outfitted with separate drive motors allowing the setting of totally different rotary speeds for carousel and spindles. The processing bowl is filled with processing media, which in this particular application consists of crushed walnut shells and aluminum oxide. A vibratory motor mounted below the processing bowl ensures the optimum mixing of the processing media. Required bowl changes can be quickly carried out with a forklift truck. For the actual process the tools to be finished are manually mounted to specially designed work piece fixtures, which in turn are attached to the spindles equipped with quick-connect couplings. To facilitate this operation, the operator moves the spindles to the load/unload station with the touch of a button. This allows quick, ergonomic and simple loading/unloading of the work pieces. Once the respective processing program, stored in the programmable system controls, has started, the carousel with the spindles is lowered so that the rotating spindles are immersed in the processing media. Carousel and spindles are moving clock- and counterclockwise at the defined rotary speeds. At the midpoint of the processing cycle – depending on the tools to be finished, the total finishing time varies between 15 and 45 minutes – the rotary direction is usually changed. This guarantees an even radiusing of the tool edges on all sides. Continuously growing work piece spectrum shortens the amortization period Initially it was planned to use the drag finisher for five frequently used tool types. Hannes Winkler reports: „The new mechanical drag finishing system produced such good results that the usable life of these components could be practically doubled. And in some instances it could even be increased by a factor of ten. Since commissioning the drag finisher about six months ago, we have increased the spectrum of work pieces to be finished mechanically to around 20 different tool types. This helped reduce the amortization period to well below two years. By continuously adding additional work pieces, the amortization time will decline even further”. This positive experience led the voestalpine group of companies to list Rösler as the exclusive supplier for this particular finishing application. Besides the mechanical edge radiusing of additional tool types, the process optimization specialist is also considering a polishing application. Hannes Winkler concludes: „At the moment we are conducting processing trials. If the results are as we expect, we will purchase a second processing bowl with the required processing media. A key advantage of the Rösler drag finisher is that processing bowls can be easily exchanged allowing us to quickly switch from one application to another”.

Monitor Wear Linings to Maintain Process Efficiency, Increase Equipment Longevity

Mass finishing machinery is a major investment for most companies. Proper maintenance and preventative repairs over the life of these useful and necessary machines will greatly improve the return on such investments, drive productivity, and extend the working life of the equipment itself. Rosler stresses the need to regularly inspect the linings of vibratory tubs and troughs to identify repairable issues before permanent damage occurs. Media-Induced Wear To effectively finish work pieces, media must be matched to the specific finishing task and initial state of a work piece. For example, media used for deburring/edge radiusing and surface grinding can be very abrasive. If not properly protected by a suitable wear lining, the steel construction of a work bowl would be completely worn through in a few hours by contact with the media and work pieces. Polyurethane and, to a certain degree, rubber are excellent lining materials providing wear protection for thousands of operating hours. Even these materials wear though and must be periodically replaced with a new lining. (More information about specifying liner materials is available in a previous blog post .) Maintaining Process Stability Checking your work bowl lining for wear and replacing it in a timely manner is essential for the stability of your mass finishing process as a whole. In addition to worn work bowls, failure to ensure a proper protective lining can create other problems including: Work pieces getting stuck in the machine and, therefore, jeopardizing the integrity of different work piece batches. Media, water, and process chemicals can leak from the machine if the metal processing bowl is worn through and holes or cracks appear. Severe machine malfunction can occur when media or parts can get trapped in worn spots during the separation phase when the finished work pieces are separated from the media. Damage to the work bowl that is beyond repair, causing an unnecessary downtime and requiring costly replacement parts. A weakened bowl can crack and make the entire machine unusable Check your bowl lining at least monthly for wear or rips. Especially the areas around drains, the parts loading chute, and around the unload areas will see the highest wear. The “nail test” makes checking the liner thickness easy. Push a nail trough the liner until you hit the base metal and record the thickness of the liner. Keep track of the liner thickness over time to predict when you will need to replace your liner. Just as optimal media mix must be regularly monitored, so must the condition of a work bowl. If not, the entire process and downstream operations may suffer. Reline Expertise This work bowl is being relined with sprayed‐on polyurethane at a Rosler reline shop. Rosler maintains a shop offering reline services for work bowls of all types and makes. With the unique Rosler ThermoStrip procedure, we can patch and repair worn work bowls to restore process efficiency and extend the life of your equipment whether Rosler designed it or not. The Rosler Way Our worldwide network of service providers is positioned to provide expert service and guidance. Contact us to discuss how we improve your process and increase the lifespan of your equipment.

New technology and test center for Rösler brand AM Solutions – 3D post processing technology

The ideal environment for process and product development for post processing of 3D printed components The new technology and test center of AM Solutions – 3D post processing technology represents a significant milestone in the development of processes and products for the post processing of products created with AM methods. The new center is outfitted with state-of-the-art engineering software and various 3D printing systems. However, the main focus is on an exceptionally well-equipped post processing section, where AM Solutions – 3D post processing technology can demonstrate an impressive range of machinery for post processing of 3D printed components. Additive manufacturing allows the quick and flexible production of metallic or plastic components with precisely defined material characteristics. All these components have one thing in common: Their surface requires different kinds of finishes, which must comply with the most stringent finishing specifications. These requirements pose a special challenge for the post processing of 3D printed components. AM Solutions – 3D post processing technology is meeting this challenge head-on with its new, generously equipped technology and test center at the company’s location in Untermerzbach. State-of-the-art technologies along the complete AM process chain under one roof In its new test center with a total area of 400 square meters, the Rösler division specializing in 3D post processing solutions, can demonstrate the complete process chain of additive manufacturing. Manuel Laux, Head of AM Solutions – 3D post processing technology, explains: “It is our declared goal to develop the best possible process solutions for our customers. To do this we must be able to fully understand every detail of the additive manufacturing process and must actually be in a position to demonstrate the various manufacturing stages. Only with such a hands-on approach will we be able take into account all the facets of additive manufacturing.” The new test center is not only equipped with the latest engineering, printing and post processing hard- and software, but the actual building was also carefully prepared, For example, suitable air intake and venting systems were installed to maintain exact temperature and humidity levels in the pressure area. For engineering and topology optimization the center is utilizing NX CAD software from Siemens. The 3D scanner Atos from GOM allows quick and precise optimization of engineering operations. In addition, it is also utilized for quality control. The printing sections are strictly separated by material categories, and the actual printing equipment is placed in vibration absorbing areas. Metallic materials are printed with an EOS M 290 system, whereas for the creation of plastic components a Polyjet printer Objet 260 Connex 3 from Stratasys, a Multi Jet Fusion printer HP Jet Fusion 3D 5200 and a FDM printer are available. To allow test trials for the development of optimum, automated post processing solutions and to select the most suitable equipment, AM Solutions – 3D post processing technology installed its own post processing equipment line in the form of the models S1, S2 and S3 as well as M1, M2 and M3. Moreover, the test center is equipped with various post processing systems from the AM Solutions partners GPAINNOVA and PostProcess Technologies. These include a GPAINNOVA DLyte 100 and the first installation in the world of a DLyte 10.000. In addition, the DEMI, DECI, DECI Duo and Rador from PostProcess Technologies are available for test trials. With such a comprehensive equipment portfolio the new technology center is an ideal partner for the efficient specification and development as well as optimization of customer specific processes and products for post processing of 3D printed components. This includes unpacking, removal of support structures, stripping of loose as well as sintered-on powder from the work pieces, but also general cleaning, surface smoothing, edge radiusing and, even polishing.

Intelligent Multi-Tumbler solution produces absolutely consistent shot peening results on spring band clips

Quick, efficient and gentle processing of work piece batches A leading, globally active automotive supplier increases the tensile strength of spring band clips by shot peening. For this purpose the company purchased a second Rösler shot blast machine for its plant in Poland. The Multi-Tumbler RMT 70 shot blast machine, equipped with a highly wear-resistant Rutten high-performance turbine, was designed for fully automatic operation including loading and discharging of the work pieces. A simulation of the work piece behavior provided valuable design pointers making sure that in the actual barrel the work pieces are perfectly mixed. This guarantees the safe and gentle processing of the work piece batches and shortens the actual peening time. When it comes to developing and manufacturing of automotive components for lowering weights and reducing CO2 emissions, the worldwide active Mubea group is without any doubt one of the global leaders. The company’s products include components for automotive chassis, car bodies and drivetrains. Besides serving the automotive industry, the Mubea group also manufactures components and assemblies for aerospace and home appliances and offers custom-engineered solutions for other industrial applications. With over 700 different types Mubea also markets the worldwide largest range of spring band clips, generally known as hose clamps. More than one billion of these hose/pipe union connection elements are produced at locations in Europe, Asia and North & South-America. Simulation helps reduce the cycle time for peening of spring band clips To make these components, manufactured from high-strength alloyed tool steel, more resistant against the constantly changing loads in vehicles, their tensile strength is improved by shot peening them. For this purpose the Mubea Automotive Poland sp. zo.o. purchased a second Rösler shot blast machine. The Multi-Tumbler RMT 70 allows the fully automatic shot peening of spring band clips in batches weighing up to 1,800 kg. A key factor in the customer’s decision for this machine type was the unrivalled geometry of the blast barrel. A simulation of the work piece behavior in the blast barrel provided valuable design pointers making sure that the work pieces are perfectly mixed. This helped shortening the actual peening time. The unique barrel design also helped prevent any rejects by work pieces getting stuck and, thus, helped improve the overall productivity. High cost efficiency and reduced requirements for maintenance To comply with the strict specifications of Mubea Automotive Poland, the Multi-Tumbler is equipped with a Long Life Rutten blast turbine with curved throwing blades in “Y” shape and an installed power of 30 kW. The precisely calculated curvature of the blades generates an extremely high throwing speed along with a precise media guidance. This results in an optimal blasting efficiency. At the same time the turbine requires a lot less energy reducing the energy consumption by up to 25 %. The throwing blades are made from a highly wear-resistant alloy, and their special “Y” design allows using both blade sides. For this reason – depending on the used blast media – the Rutten high performance turbines achieve a 10 to 16 times higher uptime compared to conventional blast turbines. This results in a significant increase of the equipment availability and drastically lower costs for maintenance. An automation concept that is precisely tuned to the customer’s requirements To completely automate the shot peening process, the shot blast machine was equipped with a special work piece loading system that includes a weighing cell and the required software integration. This allows calculating the optimum batch weight during the automatic work piece load operation. The PLC adapts the shot peening time to the actual weight of the respective work piece batch. Throughout the peening operation the barrel is completely sealed with a lid. The barrel and turbine RPM are automatically adjusted with frequency inverters. All these features, combined with the optimum mixing of the work pieces in the barrel, make sure that absolutely consistent, repeatable peening results are achieved in surprisingly short cycle times. Of course, the continuous monitoring of all critical process parameters also contributes to the process safety and stability. The blast media recycling and cleaning system is adapted to the overall system and guarantees the consistently high blast media quality required for the shot peening process.

Wet Blasting Technology, Part 1 – Wet Blasting Gently Delivers Dramatic Finishing Results

Thanks to its many technical advantages and “gentle” application, wet blasting is a versatile and fast-growing segment of the shot blasting field. Achieving precise, repeatable results with any wet blasting process requires understanding both its principles and real-world uses. With decades of experience and the latest in engineering expertise, Rosler understands how to develop efficient wet blasting machines and consumables . Learn more about wet blasting technology as we begin our five-part Wet Blasting Technology Series. How Does Wet Blasting Work? Wet blasting is a water-based method of shot blasting utilizing abrasives that are particularly suited for the finishing of delicate, precision-produced parts. Rosler Wet Blast Gun Schematic The blast medium consists of a slurry of water and an abrasive media placed in a tank. This slurry is supplied to the blast gun from the tank with a special pump and accelerated with compressed air. The compressed air creates a venturi effect at the blast gun nozzle. The accelerated slurry, pushed through the blast gun nozzle, is then thrown at the work pieces at high speed. The impact on the work piece surface creates the desired blasting effect, be it cleaning, coating preparation, cosmetic surface texturing, or peening. The concentration of abrasive media in the slurry usually amounts to 10-40% by volume. For example, 20% media and 80% water, etc. For consistent process uniformity and high-quality surface finishing of the work pieces, the control of the blasting nozzles in Rosler wet blasting machines is assumed by industrial robots or by CNC systems. Loading and unloading can also be automated in many ways, and the individual production requirements implemented. What is Wet Blasting Used for? Useful for any surface treatment task dry shot blasting is used for, wet blasting provides surface improvement, cleaning , preparation, decoating , preparation for initial coating, deflashing , and shot peening . Wet blasting is also ideal for stripping paint and coatings from delicate parts. High water content in the slurry allows wet blasting to be a lot more gentle than dry blasting. Therefore, it is ideal for processing delicate work pieces with thin walls, which, if treated with dry shot blasting, might be subject to heat warping. Wet blasting creates very smooth cosmetic finishes. To a certain degree, it can also be used for cleaning of work pieces contaminated with oil or grease, for example, for engine and transmission re-builds or aircraft MRO work . Wet blasting has also become indispensable for initial surface smoothing of additively manufactured components made from plastic and metal. Special surface finishes can be achieved by selecting different blast media materials such as ceramic beads and other mineral abrasives. In addition, the wet blasting process eliminates the risk of dry dust explosions and can ensure that you are meeting more stringent hazardous dust exposure limits. The Rosler Way With more than 80 years of experience in surface finishing, the Rosler team has expertise in the wet blasting field. 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!

Dewatering of paint sludge with centrifuges

90 % cost reduction combined with a positive environmental impact Wet absorption systems are the standard method to catch and discharge overspray from paint booths. For dewatering of its paint sludge a Polish paint shop purchased a cleaning centrifuge from Rösler. With sizable cost savings this investment paid for itself within the first year of operation. At the same time the dewatering of the paint sludge by centrifuge saves resources and is more eco-friendly In 1996 the painting job shop Hannex, located in Ordzin, Poland, started with the manual wet painting of components for household appliances. Since then the company has developed into a sophisticated operation with modern work places for manual paint applications as well as several fully automatic painting lines equipped with 6-axis robots and computer controlled paint supply systems. The company is coating metal, plastic and glass components with solvent- and water-based wet paint materials. Krzysztof Iwanicki, general manager at Hannex, explains: „Besides the household appliance industry our customers also include automobile companies and their suppliers around the world. A focus on costs and the environment To ensure top quality and cost efficiency, the company utilizes the latest paint application technologies from renowned suppliers. This helps reduce overspray but does not prevent it completely. The catching of the paint mist takes place with the classic Venturi wet absorption method. This uses atomized water to pick up the excess paint particles in the paint booth and discharge the paint/water mixture into three collecting tanks with a total volume of ten cubic meters. To maintain the stability of the process water various chemicals had to be added for controlling the pH value, for defoaming and for protection against bacteria infestation. The addition of coagulants and flocculants made sure that the paint particles were separated from the water and floated to the surface. The resulting sludge was then removed from the surface and pushed into a separate container with a sludge scraper. Subsequently, it was disposed of. On average about 4 tons of sludge and dirty water accumulated per week. The professional disposal of this waste material was not only extremely expensive, but under environmental aspects the resulting high consumption of fresh water was not very eco-friendly. Last-but-not least, this paint sludge disposal system also caused an unpleasant odor, a real nuisance for the employees. Krzysztof Iwanicki continues: „These disadvantages had annoyed me for quite some time. Therefore, I became very interested in paint sludge dewatering with a cleaning centrifuge and was grateful to Filip Kapela, the representative of Rösler Oberflächentechnik in Poland, informing me about this possibility in 2016”. After this first information a joint visit at the headquarters of the equipment manufacturer was arranged. During his visit Krzysztof Iwanicki was able to acquaint himself with the working principle and the performance characteristics of centrifugal filters for paint sludge dewatering. The general manager remembers: „I immediately specified my requirements and subsequently decided to purchase a centrifuge RZ 120 M-V”. Efficient separation of solids and water from the paint sludge The semi-automatic cleaning centrifuge can handle a volume of 120 liters per minute. A feed pump continuously feeds the process water into the centrifuge drum, rotating at a speed of 2,750 RPM. The high rotational speed ensures not only an excellent performance in terms of throughput, but it also ensures that very small and light-weight particles are deposited on the drum wall as solid sludge with a residual water content of 20 to 30 %. This represents a significant improvement over the sludge scraper with the residual water content of the sludge amounting of more than 80 %. Once the sludge load in the drum has reached about 22 kg, the sludge can be easily removed by simply extracting the sludge basket out of the drum and dumping the sludge into a waste container. Alternatively, in fully automatic centrifuges the sludge can be removed from the centrifuge drum with a stationary peeling knife. During the separation cycle this peeling knife is positioned in the center of the drum. For sludge peeling mode the knife moves slowly towards the drum wall by way of a pneumatically activated linear guide. The peeled out sludge falls into a container placed below the centrifuge drum. This peeling knife arrangement prevents any additional load on the bearings of the rotating drum. After completion of the peeling cycle the drum is automatically rinsed out for removal of any residual sludge deposits, which, during the subsequent cleaning cycle could cause an imbalance with the risk of premature bearing failure. The cleaned process water, now free of paint particles, is fed back into the process with a special water collection tube. Quick amortization combined with high cost savings Because of its small footprint Hannex decided to purchase a semi-automatic centrifuge. The RZ 120 M-V is equipped with sophisticated controls and a process water and clear water tank. It is not only easy to operate and maintain, but because of its placement on a movable base, it can be easily utilized at the different collecting tanks. Krzysztof Iwanicki explains: „The centrifugal cleaning process is so effective that we no longer need any coagulants and flocculants for supporting the separation of the paint particles from the water. We could also eliminate all the other chemicals for stabilizing the process water in the collecting tanks. As a matter of fact, we are only using chlorine for disinfecting the reclaimed water coming out of the centrifuge in crystal clear condition”. But the savings by no longer having to use chemicals are not the only reason for the substantial cost reduction. Because of the drastically decreased residual water content the amount of paint sludge that must be disposed of has become a lot smaller. And finally, a lot less fresh water is required for the collection of the overspray paint mist. Krzysztof Iwanicki concludes: „The centrifuge has been in operation since 2016. It amortized itself already within the first year. And we could reduce the operating costs for paint sludge removal by roughly 70 %. Beginning with the second year of operation our annual cost savings increased to 89 %”. Besides the sizable cost reduction Krzysztof Iwanicki is also very pleased with the much lower consumption of resources and the positive effect on the environment. This undeniable success prompted him to purchase a second centrifuge for cleaning the water that is used for the general cleaning of the paint booths at Hannex.

Special turbines for shot blasting in the forge and foundry industry

30 percent longer service life and lower operating costs The special version of the easy to maintain Rösler blast turbines Gamma 400G-8 has been perfectly adapted to the harsh blasting conditions in foundries and forge shops. Designed with 8 throwing blades and made from extremely wear resistant tool steel, the Gamma 400G-8 turbines offer an up to 30% longer service life than conventional turbines. Moreover, the Y-design of the throwing blades ensures a more effective and energy efficient acceleration of the blast media. This results in lower operating and maintenance costs combined with a significantly higher equipment availability. Sand, oxide, scale and residue from the tempering process on castings and forgings inevitably cause the blast turbines to wear a lot faster and lead to higher operating and maintenance costs. Rösler Oberflächentechnik GmbH has tackled this problem head-on by developing the Gamma 400G-8. This turbine variant is especially wear resistant and offers the ideal solution for such challenging shot blasting applications. It can be easily installed in all turbine shot blast machines irrespective of the original manufacturer. Equipped with a power input of up to 37 kW, the direct drive Gamma 400G-8 turbines allow a blast media throughput of up to 460 kg/minute. 8-bladed wheel design and tool steel guarantee a longer service life A key feature of these special turbines is the 8-bladed wheel design ensuring a greatly improved blast pattern. In addition, the forged throwing blades, impeller and control cage are made from high-quality, extremely wear resistant forged steel. Likewise, the turbine housing is lined with the same material. Compared to conventional turbines, this results in an up to 30% longer service life. And the patented Y-design of the blades allows using both blade sides, which practically doubles their usable life. An innovative quick-change system allows a quick and easy blade change without having to touch the other turbine components. The time consuming dismounting of impeller, control cage and inlet tube is no longer necessary. Improved performance and higher energy efficiency Another advantage of the Y-design with the precisely calculated blade curvature is a considerably better performance that expresses itself by a significantly higher throwing speed and a highly precise blast media delivery. The resulting improvement of the blast performance requires much shorter cycle times. Finally the energy efficient blast media delivery reduces the energy consumption by up to 15%. All these features uniquely qualify the custom-engineered Gamma 400G-8 turbines for use in foundries and forge shops. They offer a tremendous potential for not only reducing the operating and maintenance costs but, at the same time, increasing the shot blast capacity and overall cost-efficiency.