New turbines from Rösler guarantee improved equipment availability and a 25% higher blast performance
Secure spare parts supply and improved blast performance, these were the reasons why a manufacturer of saw bands invested in ultra-modern new turbines for a belt shot blast machine. The customer chose the Rutten Gamma 330-HD high performance turbines from Rösler not only because of their extremely wear-resistant design. He was equally impressed by the 25 % higher blast performance with, at the same time, lower energy consumption. In the meantime, the customer decided to equip other blast machines in his manufacturing organization with Rösler high-performance turbines.
The saw-bands produced by this company are known all over the world for their superb quality. These steel strip products offer excellent precision, for example, exact edge dimensions and perfect flatness. To maintain its quality standards, the company makes all its products in Germany, even though around 90 % are exported to other countries. A key stage in the manufacturing process is a shot blasting operation in a belt blast machine.
Improved shot blast performance and secure spare parts supply
The machine used for this shot blast operation, supplied by a manufacturer in Southern Europe, urgently needed to be modernized. Therefore, the engineer responsible for streamlining manufacturing operations discussed the customer requirements with the Rösler team during a visit at the Deburring Expo exhibition. The topic of this conversation was not only a secure spare parts supply and first-class technical service but also improved blast performance to provide a higher work piece thruput. Based on the detailed process parameters provided by the customer, Rösler developed a technical concept and submitted a quote for retrofitting the turbines on the existing blast machine. The quote included the installation of two high-performance Rutten Gamma turbines, type 330-HD, each with a power of 7.5 kW. This corresponds to the power of the original turbines. The feasibility of the offered turbines was proven through extensive processing trials in the Customer Experience Center at Rösler with the actual customer work pieces.
Faster blast cycles with less energy consumption and lower wear
The high performance of the Rutten Gamma turbines is based on their special design. They contain four Y-shaped throwing blades with a precisely calculated blade curvature. This guarantees an extremely precise blast media acceleration and delivery at maximum throwing speeds and, compared to conventional turbines, a significantly improved shot blast efficiency. The new turbines increased the blast performance of the existing shot blast machine by roughly 25 % and, thus, produced a significant increase of the shot blasting capacity. Moreover, the efficient blast media delivery offers savings in energy consumption of up to 25 %. The throwing blades are made from an extremely wear-resistant steel alloy, and their special design allows the use of both blade sides. Therefore, depending on the utilized blast media, the Rutten high performance turbines guarantee a 10 to 16 times longer service life than conventional turbines. These technical features, combined with the reliable and fast Rösler spare parts service, ensure a significantly higher equipment uptime with, at the same time, lower costs for maintenance.
Quick turbine exchange and optimization of the entire shot blast machine
The turbine exchange on the blast machine, originally supplied by another manufacturer, was achieved in a relatively short time period. Besides a relatively minor adaptation of the original mounting flange, it required no additional modifications. At the same time the turbines were replaced, the maintenance team of the customer and Rösler engineers fine-tuned the existing shot blast machine to the higher blast performance. Among other steps, the blast chamber was lined with additional wear plates.
About one year after the new turbines were installed, this saw band supplier is extremely satisfied with the Rutten high performance turbines. Therefore, he plans to modernize additional blast machines in his manufacturing organization, which were supplied by the manufacturer in Southern Europe.
