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Surface Preparation Standards, Part 2 – Dust Measurements and Considerations

As an expert in the surface finishing industry, Rosler knows that all the expertise in the world won’t do any good if the surface of the work piece is not properly prepared. When it comes to structural steel , we receive many questions about preparation. Among the most common questions is, “ How is the presence of dust on shot-blasted structural steel components evaluated?” Understanding dust considerations and mitigation will help produce higher quality and longer-lasting structural steel components more cost-effectively and safely. The Dangers of Dust Blast-cleaned structural steel surfaces must be completely free of dust to ensure proper coating and painting. Residual dust will reduce the adhesion of subsequently applied coatings and, by absorbing moisture, may promote the corrosion of the blast‐cleaned steel surfaces. The potential accumulation of dust is especially critical on horizontal surfaces, the interior of pipes, and inside structural cavities. Special inspections must be carried out to ensure that such areas are adequately cleaned and free from dust before painting. Standards of Assessment The most common standard of assessment for dust is ISO 8502–3:2017. Also known as the pressure‐sensitive tape method, this ISO standard describes a procedure to test shot blasted steel surfaces for dust and provides a reference description and photo with six dust ratings for comparison. On a scale of 0 to 5, the observation of dust particles and diameter are rated as follows: Visual rust scale 0 – No particles are visible under 10x magnification. 1 – Particles are visible under 10x magnification but not with normal or corrected vision; particles are usually less than 50 μm in diameter. 2 – Particles are just visible with normal or corrected vision; usually between 50 and 100 μm in diameter. 3 – Particles are clearly visible with normal or corrected vision; up to 0.5 mm in diameter. 4 – Particles are clearly visible; between 0.5 and 2.5 mm in diameter 5 – Particles are clearly visible; larger than 2.5 mm in diameter Testing for Dust ISO 8502 testing kit Special ISO 8502 kits include a 10x magnifier, adhesive tape to ISO 8502‐3 specification, comparator display board/operating instructions, a dust assessment plate, and 25 test record sheets. Proper procedure is required to accurately test for ISO 8502-3 using the kit. Remove a piece of tape about 8 in (200 mm) long. Place the sticky side of the tape onto the test surface; rub along the length of the tape using constant pressure several times. Pull the tape away from the test surface, compare the dust on the tape with the comparator display board and record the estimated dust rating number. Repeat the test at least three times on the surface being investigated. Minimum Requirements The dust test per ISO 8502‐3 is subjective and does not allow the precise determination of dust on a blast cleaned surface, but the rating can be a very useful approximation when carried out by experienced operators. Painting schedules usually call for shot blasted surfaces prior to painting to be free of dust. A generally accepted rule stipulates that the particle quantity and particle size do not exceed rating 2 of ISO 8502‐3. Rosler blow-off station Removing Residual Dust To remove residual blast media and dust from the work pieces shot blasted steel components are usually passed through a blow‐off station. These stations are frequently combined with a brush‐off system. The Rosler Way Rosler has more than 80 years of experience developing surface finishing technology and systems. We are confident that we can answer your surface finishing questions and develop a solution to meet your needs. Contac t us today to discuss your unique challenges. Additional information about surface preparation standards is available in Part 1 of this series, “Evaluating Surfaces Throughout Finishing Processes.”

Surface Preparation Standards, Part 1 – Evaluating Surfaces Throughout Finishing Processes

Surface preparation can account for up to 40 percent of structural steel painting and repainting jobs and the life of anti‐corrosion coatings on a steel surface largely depend on how thoroughly the surface was prepared before painting. At Rosler , we have extensive experience evaluating structural steel surfaces for coating before and after shot blasting. This knowledge of surface preparation standards and the widely used ISO and SSPC standards guide us in developing systems to expertly prepare and repair structural steel throughout its lifespan. The Standards Evaluating rust and mill scale pre- and post- shot blasting is a must. It is important to clearly specify the quality of the surface prior to preparation as well as the surface conditions after preparation. As a result, standards were developed to visually assess the initial surface conditions and the quality of the required surface preparation relative to the initial steel surface conditions. The dominant and widely used standards for evaluating rust and mill scale are ISO 8501‐1:2007 (based on the Swedish Standard SIS 05 59 00) and the SSPC (Steel Structures Painting Council) . While different in some minor details, these standards are practically identical. Pre-Paint Conditions In specifications relating to the preparation of surfaces prior to painting, the SSPC and SIS designations correspond as follows. Corresponding SSPC and SIS designations Rust Grades The standards identify four initial rust grades based on visual evaluation before surface treatment. The following examples illustrate and describe the four ratings. Visual comparison of rust grades A – The steel surface is covered completely with adherent mill scale and little, if any, rust. B – The steel surface has begun to rust and mill scale has begun to flake from the surface. C – The steel surface on which the mill scale has rusted away or from which it can be scraped, shows little pitting visible to the naked eye. D – The steel surface on which mill scale has rusted away shows considerable pitting visible to the naked eye. Preparation Grades After blast cleaning, the standards define four preparation grades. The appearance of the shot blasted surface must correspond to one of the following descriptions and standards: The cost to achieve longevity of each grade varies and should be considered based on initial cost as well as lifetime costs based on your structural steel’s uses and expected lifespan. Brush‐off – After light blast cleaning loose mill scale, rust, and foreign matter are removed. Despite being the least expensive grade of the four, brush-off preparation may not hold paint and coatings as well as the other grades and often requires more frequent resurfacing. Commercial – Thorough blast cleaning removes almost all mill scale, rust, and foreign matter. While normally adequate in a non-corrosive atmosphere, this grade is a more labor- and cost-intensive option compared to brush-off preparation. Near White – Very thorough blast cleaning removes mill scale, rust, and foreign matter to the extent that the only remaining traces are light stains in the form of spots and stripes. This grade is fully acceptable for most somewhat-corrosive environments. It is the most common preparation grade for ship building and most industrial and commercial weldments and fabrications. White Metal – Blast cleaning reveals pure metal. This grade is very expensive and typically reserved for applications in which the costs of coating failure are catastrophic, for example, for tanks containing highly corrosive, hazardous chemicals. Preparation Grade Examples Based on ISO 850-1 The different preparation grades depend on the initial rust grade. ISO 850-1 standard grades are presented below to provide visual examples. SSPC Vis 1/89 incorporates similar visual comparisons. Visual comparison of preparation grades The Rosler Way Whatever your pre- and post-treatment goals, count on Rosler to help you find a better way. To demonstrate our capabilities, we offer FREE sample processing in our global test centers . Contact us to discuss your surface finishing goals and challenges. Learn more about surface preparation standards in part two of the series, “Dust Considerations and Measurement” , and sign up for enews alerts to be notified of all new posts!

Interlinked, automated shot blasting system improves the quality and reduces costs

When a Polish manufacturer of complex steel weldments was ready to invest in a new shot blast machine, quality, capacity, high equipment uptime and integration into the manufacturing flow were the key selection criteria. As an essential part of the pre-treatment operation for a cathodic painting line, the new shot blast system had to produce optimal surface preparation results within an interlinked work flow in a 3-shift operation. The company chose a Rösler RHBD 17/32-K continuous feed spinner hanger blast machine because of its wear-resistant design and favorable operating costs. The specialty of the Stelweld Sp.o.o. is the production of complex steel weldments, including machining, laser and CNC cutting, bending as well as wet painting and powder coating. With this market philosophy the company, founded in 1997, has established itself as a key supplier for such diverse industries as automotive, agricultural and construction equipment, cranes, including all kinds of lifting equipment, renewable energy and rail transport. Among many other companies Stelweld also sells its products to Scania, Volvo, Bombardier and Cargotec. In the year 2019 a new building was erected to provide space for a new, fully automated cathodic painting line (KTL) with 16 operating stations and a power & free transport system. Danuta Dobrzynska, project manager at Stelweld, comments: „Within the framework of this expansion we also wanted to automate the shot blasting operation and integrate it into the painting line. To date, the paint preparation process was predominantly done manually”. Sturdy equipment design and convincing test results A high capacity, excellent shot blasting results, an outstanding equipment uptime and a high cost efficiency were the other key selection criteria. Among the five shot blast equipment manufacturers who were considered as potential suppliers, the customer chose Rösler with its continuous feed spinner hanger blast machine RHBD 17/32-K. „I was familiar with Rösler through a project I dealt with, when working for another company. Rösler does not offer the lowest price. But with regard to quality and technical features this supplier offered many advantages. Compared to the competitive products all essential components of the Rösler shot blast machine consist of wear-resistant materials, such as the throwing blades of the turbines, which are made from forged tool steel”, explains Danuta Dobrzynska the decision for Rösler and continues: „Another key factor for our decision were the results of the shot blasting trials that were conducted with some of our original components. In the Customer Experience Center at Rösler we achieved excellent shot blasting results, which provided valuable pointers for our actual shot blasting operation”. Technical features that ensure excellent results, outstanding efficiency and high uptime The continuous feed spinner hanger blast machine RHBD 17/32-K allows the blast cleaning of a very wide spectrum of three-dimensional weldments with dimensions of up to 2,500 x 1,200 x 3,000 mm (L x W x H) and weights of max. 1,250 kg. At cycle times of 6 to 8 minutes the automatic shot blasting process produces a finishing quality of SA 2,5 on the entire surface of the steel weldments and surface roughness values that are in full compliance with the standards defined by Stelweld and its customers. This ensures an excellent paint adhesion on the work pieces. To achieve such demanding results, the shot blast machine is equipped with 16 Gamma 400G turbines, each with a drive power of 15 kW. These high performance turbines, developed by Rösler, are furnished with throwing blades in “Y” design. Compared to conventional turbines, the special blade geometry with its precisely calculated curvature produces a very high throwing speed with, at the same time, a lower energy consumption. This results in an up to 20% higher shot blast performance. Moreover, because of their symmetric design both sides of the throwing blades can be used resulting in a two-fold increase of the usable blade life. Thanks to a special quick-change system blade changes can take place without having to dismount the turbine. The turbine placement (position and angle) was determined with a special simulation of the shot blast process. The highly focused blast pattern also contributes towards the high efficiency of the shot blasting process. In order to adapt the blast media throughput of up to 200 kg/min to the geometry of its steel components, Stelweld is utilizing three different shot blasting programs. The rotational speed of the turbines is adjusted by frequency inverters. This allows the precise control of the impact energy of the blast media on the work piece surface. For optimum wear protection and, thus, a long equipment life, critical sections of the inlet and outlet chamber are fabricated from 6 mm thick manganese steel. The same material, this time 8 mm thick, is used for the blast chamber. Furthermore, the blast chamber is protected by overlapping, easy-to-replace wear plates made from high-strength materials. Sturdy rubber curtains in the inlet and outlet chamber, as well as the protection of gaps with multiple rubber seals and brushes, prevent any blast media spillage to the immediate environment. „The turbines, the entire equipment design and the used materials guarantee a high uptime. This ensures a safe, trouble-free and energy-efficient operation”, concludes the project manager. Fully automatic, interlinked operation produces repeatable high quality The power & free transport system transports the steel weldments, containing a QR code for the automatic selection of the respective shot blast program, to the shot blast machine. As soon as a trolley with one work piece has entered the inlet chamber, the double leaf doors are closing, and the turbines, the blast media return system and dust collector are starting automatically. During the shot blast process the work piece is passing through the blast chamber at a pre-defined speed. The 16 blast turbines ensure an intensive cleaning of all work piece areas with highly homogeneous and consistent shot blasting results. Two dropout boxes placed in the duct connection between shot blast machine and dust collector make sure that the generated dust is evacuated from the blast chamber, whereas re-usable blast media is returned into the shot blast machine. The shot blast machine is accessible behind the outlet chamber. This allows the manual removal of residual blast media from the weldments, especially those with cup-shaped sections. An auger in the bottom returns the removed blast media to the media recycling and cleaning system consisting of two cascade air-wash separators. Subsequently the blast cleaned work pieces are transported to the KTL painting line. Danuta Dobrzynska concludes: „Compared to our previous manual shot blast operation the new shot blast machine achieves considerably better and much more consistent shot blast results in a much shorter time cycle. This allows us to employ our qualified personnel for more productive work, helping us to create more added value. Through savings in energy consumption and other operating costs the overall shot blasting operation has become considerably more economical”.

Webbasierte Fernwartung: Rundum-Sorglos-Service für Ihre Strahlanlage

Um Stillstandzeiten bei Strahlanlagen möglichst gering zu halten, gehört für viele Unternehmen eine vorausschauende Wartung zum Pflichtprogramm. Bei auftretenden Problemen ist es häufig notwendig, dass Servicepersonal des Herstellers ins Unternehmen kommen muss, um die Störungsbeseitigung durchzuführen. Das kann wertvolle Zeit kosten. Schneller und individueller Wartungsservice dank Wartung 4.0 Mit unserem webbasierten Fernwartungssystem mit Ethernet Verbindungsleitung zur SPS bieten wir Ihnen die Möglichkeit, die Fehlerdiagnose Ihrer industriellen Anlagen und Geräte mittels Fernzugriff auf Abruf und in Echtzeit zu realisieren. Durch einen gesicherten VPN-Tunnel wird im Bedarfsfall mittels Kundenfreigabe eine automatisierte Datenverbindung hergestellt, die es unseren Servicetechnikern ermöglicht, eine schnelle Fehleranalyse vorzunehmen. Auch die unmittelbare Anpassung an der Maschinensteuerung ist im Bedarfsfall möglich. Hierdurch können Sie die wartungs- und störungsbedingten Ausfallzeiten Ihrer Strahlanlage erheblich reduzieren. Mehrwerte: Gesteigerte Produktivität & Wettbewerbsfähigkeit durch unverzügliche Fehleranalyse und -behebung Nachhaltige Reduzierung der Instandhaltungskosten, da Einsätze an der Anlage auf ein Minimum reduziert werden Bereits ab dem ersten eingesparten Störungsfall können sich die Kosten für das Fernwartungssystem amortisieren Technische Aspekte: Maximale Sicherheit durch integrierte Firewall mit AES/SSL Verschlüsselung Durchgehende Nachvollziehbarkeit und Zugriffskontrolle Fernwartungssystem per Hardwareschalter durch Kunden zu – und abschaltbar, d. h. Zugriff auf SPS nur bei Kundenwunsch Zugriff auf alle im Subnetz verwendeten Teilnehmer möglich (SPS, OP, Umrichter, etc.)

Patient-Specific Implants Call for Equally Customized Processing

Advancements in medical technology now allow for the development of Patient-Specific Implants (PSI). Specialized computer programs analyze x-rays, ultrasound, and MRI images to create surgical guides, tools, and implants tailored to the patient’s unique anatomy. While still emerging, many medical industry suppliers have received FDA approval for PSI use. Like traditional implants, these implants must be carefully finished once created to ensure the work piece meets stringent medical safety standards while promoting patient comfort and long wear life. The benefits of PSI use include shorter surgery times, better surgical outcomes, and cost savings. True to its “apply innovation” tagline, Renishaw’s Medical and Healthcare Division has found great success in additively manufacturing PSI. Using CT scan-to-CAD software, one of the company’s most innovative advances is creating cranial plates using titanium powder. When determining how to finish the implants to precise medical requirements and surgical demands, Renishaw trusted Rosler for help with mass finishing . The Challenge Renishaw cranial plates after polishing Original commissioning neurosurgeon Bartolomé Oliver required the surface of Renishaw’s cranial PSI to be satin-like in order to best match the patient's cranial contours. Renishaw Applications Engineer Andy Wescott's job then became creating a repeatable and streamlined process to apply a satin and highly polished finish to the top of the cranial plates from their as-built condition. "Traditionally, post-processing these parts to a low surface roughness value was very manual and time-consuming," Wescott said. "The post-process time for a large cranial plate was up to five hours. We needed to reduce that time and the amount of manual input because if an operator working on a part loses concentration for one second, they could burn a hole in your part. “That makes one expensive bit of scrap." Finding a Better Way… Since metal additively printed parts are now of such quality, they can be treated like any other metal part. And Rosler knows a thing or two about surface finishing metal parts, having been in the post-processing game with its mass finishing and shot blasting divisions for more than 80 years. A more mechanized solution presented itself in the form of Rosler’s High-Energy Centrifugal Disc Finishing Machine FKS04 . Now, after a cranial plate comes out of the Renishaw AM250 machine, it undergoes only a small amount of manual operation to remove supports from printing and slightly improve the surface using a carbide burr and flap wheel. It is then placed into Rosler’s FKS where it automatically goes through a three-step process to produce the impeccably smooth finish, reducing manual operating time to under an hour. The clever part, which ensures repeatability on each and every part, comes from a little bit of Renishaw engineering know-how. "We designed a tool to hold our parts in a particular orientation inside the tumbling bowl,” Wescott said. “Rather than just throwing parts into three media types and coming out with a sort of fixed part, our parts require precision. Certain features require protection from the tumbling media, so we've invented a tooling method that keeps parts face down in the media and only applies the surface finish where needed." The Rosler Way Although there isn’t a one-size-fits-all solution for finishing, the collaboration between Renishaw and Rosler demonstrates that post-processing doesn’t have to be a grueling experience. Much like the additive manufacturing process itself, your finishing technique depends on your unique application. Contact Rosler today for help in finding a better way to meet your finishing needs.

Croom chooses Rösler as a strategic partner

Croom Precision Medical chooses Rösler as a strategic partner for the design, manufacture and installation of a dependable orthopaedic implant finishing system. This was no exception when Croom Medical approached Rösler with their plans to expand and increase their production & throughput of medical implants. As an industry leader in utilising high-tech, high-growth, cutting-edge medical device manufacturing technology, Croom Medical has over 37 years’ experience in partnering with global healthcare companies as an outsourced manufacturing service of high precision components and medical devices. The cooperation throughout the project from Croom Medical, the end customer and the personnel involved within the Rösler organisation, both in the UK & Germany, was indispensable from the initial contact through to the final installation & commissioning. The project itself and timeframe was completed within the expected timeline and also, in part, took place under some rather complicated circumstances (COVID-restrictions and required protocol) however, with the support from all at Croom Medical to our installation and engineering team, everything resulted in a commendable operation. With the installation now in place, Croom Medical can immediately proceed with the validation processes to fulfil their promise to their customer and subsequent commitments to patients. The Rösler equipment is designed to polish implants to an agreed standard, set within the industry, where surface finishing after machining is stipulated to provide consistent and reproducible results in a controlled process. The advantage of the Rösler designed system is the ability to finish multiple implants at a time based on the required batch size, which in turn reduces overall cost per part compared to other traditional finishing methods.

Excellent finish for deep-drawn precision medical components

Deep-drawn functional components are increasingly being utilized in the production of medical and pharmaceutical products. To also meet the strict standards for manufacturing and quality management in the field of surface finishing, Stüken Medical relies on mass finishing solutions and consumables from Rösler. In order to meet the increasing demand for deep-drawn metal components in the field of medical and pharmaceutical engineering, a few years ago the Hubert Stüken GmbH & Co. KG, founded in 1931, established the business division “Stüken Medical”. The product range of this family-owned company includes also stamped and bent parts, plastic-coated components and complex assemblies. The company maintains manufacturing operations at five locations in Europe, Asia and the United States. Andreas Hellman, manager of the ISO 13485 certified business division, explains: „Components used in the field of medical and pharmaceutical engineering must meet strict quality standards. The same strict standards apply also to the actual production operations. For this reason, we have pooled the required knowhow for the development and production of such precision components at Stüken Medical”. Among other items, this division produces complex housings and assemblies, valves, extremely precise micro parts and primary packaging. These components are made from metals suitable for deep drawing, such as stainless steel, aluminum and titanium. To meet the strict quality standards in the medical and pharmaceutical industry, the company utilizes multi-stage cleaning systems and operates two class 7 cleanrooms. The company’s R&D and development department, located at the corporate headquarter in Rinteln, Germany, is continuously exploring the possibilities to expand the range of processes and materials. A team approach for innovative solutions „For many of our customers we are a development partner. To perfectly adapt new products to their intended use, we are not only working with our customers but are also cooperating with partners from various technological sectors”, continues Andreas Hellmann. When it comes to issues around surface finishing that can be resolved by mass finishing, for 30 years the company has been relying on the experience and knowhow of the Rösler Oberflächentechnik GmbH. Andreas Heilmann explains further: „Our long partnership is based on the excellent quality and reliability of the Rösler equipment and consumables. This helps us to ensure that the required results are achieved in a consistent manner”. Dirk Schulz, project engineer at Stüken, adds: „When it comes to the joint development of finishing processes, we value especially the flexibility and expertise of Rösler. In this respect, our access to the Customer Experience Center in Untermerzbach is extremely valuable. Rösler supports us also with documentations and equipment details, required for machinery and processes that must be qualified and validated in line with ISO 13485. At its manufacturing locations around the world this deep-drawing specialist is using around 15 rotary vibrators and 10 centrifugal disk finishing machines for its finishing operations. The company is also operating 18 centrifuges for the eco-friendly and reliable cleaning and recycling of the process water. Strict requirements for the finishing results The deep-drawn components are generally characterized by an extensive degree of material shaping, complex geometries and extremely small dimensions requiring a high dimensional accuracy. This results in especially demanding specifications for deburring, edge radiusing and polishing of external and internal work piece areas. Equally challenging are the surface roughness and surface quality requirements. Dirk Schulz explains: „On the one hand we must ensure that all pieces within a work piece batch receive the same high-quality surface finish. On the other hand, the work pieces must not be damaged or deformed. Last-but-not-least, after completion of the finishing process the work pieces and media must be reliably separated. A carry-over of the work pieces and/or media into the next batch must be prevented at all costs”. In conjunction with polishing jobs, the work piece surface must frequently be marked with an UDI code. To fully meet these specifications requires not only finishing processes that are precisely tailored to the respective work pieces. Likewise, the equipment and consumables must also be adapted. Frequently, this requires conducting special feasibility studies. A process for finishing medical components The process for radiusing the edges on a 20 mm large stainless steel housing for a medical device was developed in close cooperation with Stüken. The project engineer explains the finishing task as follows: „With this delicate housing the main challenge was a large surface area in combination with extremely thin walls. To remove sufficient material at the edges requires a high processing intensity. But the intensity must be tightly controlled to prevent any deformation”. The Customer Experience Center at Rösler is equipped with ultra-modern machines for running a wide variety of different finishing processes. This allows conducting processing trials for defining the most suitable equipment technology under actual production conditions. During such development processes, the processing bowl of standard machines must be frequently modified, sometimes involving substantial engineering changes. For this project, the comprehensive mass finishing experience at Stüken was a valuable source of ideas. To guarantee a reliable and complete separation of the finished work pieces from the media the finishing equipment for Stüken Medical required a few changes in the separation process. Another goal of the processing trials is the determination of the optimal media shape and type (ceramic or plastic) for the finishing task at hand. In order to achieve consistently good surface finishes, very often the media must have extremely tight dimensional tolerances. All ceramic and plastic media are produced at Rösler in compliance with the highest ecological standards. With over 15,000 different products the media, together with the compounds and process water cleaning agents, represents the by far largest range of mass finishing consumables in the world. Key factor for the development of successful finishing processes is the perfect interplay between the right equipment technology and the right consumables (media and compound). Generally, the best results are achieved by close cooperation with the customer. Photos: Hubert Stüken GmbH & Co. KG

Wet Blasting Equipment & Media, Part 2 – Technical Components Combine for Systematic Success

Wet blasting technology lends itself to a variety of processes and industries . From applying cosmetic (anti-glare) finishes and surface smoothing to deburring , de-powdering, decontaminating, and cleaning after casting, welding, and additive manufacturing , wet blasting has many capabilities. Rosler has decades of worldwide experience developing technology and machines customized to each customer’s unique challenges and demands. Each solution we deliver is innovatively designed around core wet blasting components and calibrated to your work piece with carefully selected media and tested process parameters. Basics Components Wet Blast Principle Diagram Regardless of their uses, all Rosler wet blasting machines start with a core group of components. While customized options and accessories can be added, these systems typically include 10 key components. Blast chamber with slurry tank – A mix of media and water is stored in this holding tank found at the bottom of the blast chamber. The chamber is made of stainless steel. Compressed air – Approximately 70 PSI of compressed air accelerates the slurry. Blast gun(s) – One or more guns accelerate the slurry supplied by the slurry pump with compressed air. Blast media feed – This component supplies the media slurry to the blast nozzle. Slurry pump – This high-powered mechanism transports the slurry to the blast gun(s). Larger wet blast systems can be equipped with multiple pumps. Slurry agitator (stirrer nozzle) – In order to keep the media suspended in the water, the slurry pump diverts some of its flow to a stirrer nozzle placed in the tank to agitate the mix of water and abrasives. Overflow – Small media particles, dirt, and other contaminants tend to stay suspended and are skimmed off and sent to the filtration unit. Water filtration system – Media particles and debris skimmed off the water’s surface must be passed through a filtration system to separate still usable media and process water from waste. Common filtration methods include hydrocyclones, weir tanks, bag filters, paper band filters, and semi- and fully automatic centrifuges. Filtered water – Once processed by a water filtration system, water is returned to the slurry tank and reused. Exhaust vent – The water mist mixed with media fines and other small particulates is removed from blast cabinet by suction fan-equipped filters. The Rosler Way We have the experience and expertise to meet your wet blasting needs. Rosler partners with you to find a better way, the best machine, and the best finishing results. Contact us today to discuss your unique challenges. Previous posts in the Wet Blasting Equipment & Media series include: Part 1 – “Machines Range in Complexity, Uses.” Part 2 – “Technical Components Combine for Systematic Success.” Part 3 – “Maintain Slurry Concentrations for Finishing Consistency.” Upcoming posts will include: Part 4 – “Internal Cleaning, Rebuilds Prolong Machine Lifetime.” Part 5 – “Careful Media Selection, Additive Use Impact Results.” Sign up for enews alerts to be notified of new posts!

Ausbildung & Studium in der Region: Rösler bildet seit über 43 Jahren erfolgreich aus

Insgesamt 15 junge Menschen beginnen am 01. September 2021 eine Ausbildung in einem technisch-gewerblichen oder kaufmännischen Beruf – sowie in dem dualen Studiengang der Wirtschaftsinformatik. Auch in schwierigen Zeiten will der Spezialist für Oberflächentechnik den künftigen Bedarf an bestens ausgebildeten Fachkräften selbst decken. Rösler bleibt somit ein wichtiger Arbeitgeber und Ausbildungspartner für die Region. Trotz der anhaltenden Corona-Pandemie setzt das familiengeführte Industrieunternehmen aus Franken auch in anspruchsvollen Zeiten auf eine nachhaltige Ausbildung von qualifiziertem Fachpersonal – und das seit mehr als vier Jahrzehnten. „Wir verstehen die Ausbildung als ein langfristiges Instrument und dieses braucht Kontinuität“, sagt Anja Süppel, Ausbildungsleiterin der Rösler Oberflächentechnik GmbH, die selbst Ende der 80-er Jahre ihre Ausbildung bei Rösler begann. „Das Thema Ausbildung liegt mir persönlich am Herzen. Viele der heutigen Führungskräfte haben ihre Ausbildung bereits im Unternehmen absolviert, so habe ich auch hier meine Ausbildung zur Industriekauffrau einst erfolgreich abgeschlossen. Zudem konnten wir in den letzten Jahren eine Vielzahl von Auszubildenden in ein langfristiges Beschäftigungsverhältnis übernehmen, damit sichern wir fortwährend Know-how im Unternehmen“. Spannende Projekttage verhelfen zu einem guten Start Schon fast traditionell finden in der zweiten Ausbildungswoche die Rösler Projekttage statt. Diese verschaffen den jungen Nachwuchskräften erste Einblicke in die wichtigsten Geschäftsbereiche des Unternehmens, dienen der örtlichen Orientierung und bieten zudem die Möglichkeit, sich untereinander besser kennenzulernen und als Team zu wachsen. Höhepunkt und Abschluss der Projektwoche ist das gemeinsame „Outdoor-Training“ auf dem Gelände der Freizeit- und Tagungsstätte CVJM in Altenstein. Themen wie „Knigge im Berufsalltag“ oder „Schlüsselqualifikationen“, aber auch ein „Kreativ-Workshop“ sind Topics für die ersten Tage. Mitte September startet bereits die heiße Phase für die Bewerbungen um die Ausbildungsplätze 2022. Das vielfältige Ausbildungsangebot reicht von unterschiedlichen Berufen des technisch-gewerblichen über den kaufmännischen Bereich bis hin zu dualen Studienangeboten. Die Rösler-Gruppe bietet für das Jahr 2022 folgende Ausbildungsplätze an: Industriekaufleute, Chemielaboranten, Technische Produktdesigner, Konstruktionsmechaniker, Industriemechaniker, Mechatroniker, Elektroniker für Betriebstechnik, Fachkräfte für Lagerlogistik, Fachinformatiker. Ein dualer Studiengang ist möglich im Bereich Wirtschaftsingenieurwesen, Wirtschaftsinformatik, Elektrotechnik oder Maschinenbau. Die Partnerhochschule von Rösler ist die Duale Hochschule in Mosbach. - Unabhängig von der Formulierung richten sich alle Ausbildungsangebote an alle Geschlechter gleichermaßen. - Online-Bewerbungen sind ab sofort möglich über die Internetseite: www.rosler.com Bei Fragen zu Ausbildung/Dualem Studium gibt Anja Süppel gerne Infos unter Tel.: +49 9533 / 924-442 oder per E-Mail an: a.sueppel@rosler.com

Centrifuge Technology, Part 5 – Potential Issues and Remedies for Water Recycling

Trial and error are often the origin of innovation. As such, mass finishing and centrifuge technology have been advanced by building upon what worked and avoiding what didn’t. With more than 80 years of experience, Rosler has extensive engineering knowledge and troubleshooting skills. An overview of the top three issues centrifuge water recycling systems experience along with possible remedies are summarized here. As always, trust a partner such as Rosler to consult on your specific issues. Excess Oil in the System Too much oil may be carried into the finishing system by the work pieces, for example, in stamping operations. The excess oil will negatively affect the mass finishing process. The media might become “glazed” causing longer processing times and poorer finishing results. In addition, the finished work pieces may also be contaminated with oil residue. Possible remedies include cleaning of the work pieces prior to mass finishing, for example, with an industrial washing machine, or switching to an alternative oil type that can be better emulsified by the compound for better discharge from the process water. Soft Water Process water that is very soft (i.e. less than 70 ppm or 4.2 gpg) can cause excessive foaming, especially, when plastic media is used. To correct this issue, make sure that you are using special recycling compounds , which are formulated to prevent excessive foaming such as Rosler compounds with the prefix ZF. Use of a defoamer, such as Rosler products ES 3, ES 4, and ES 7, can also correct excessive foaming caused by soft water. Bacteria & Fungus Contamination A very pronounced, foul smell from the process water often indicates bacteria or fungus contamination in the process water. Such contamination can be caused by a variety of factors, including: Longer shut‐down times and stagnation developed over the weekend or during process repairs and plant shutdowns. Too much oil carried into the finishing system, for example, by stampings. Dirt deposits in the form of media and metal fines in the water tanks and the piping. Numerous remedies are available based on the specific cause of bacteria and fungus accumulations, including: Using higher concentrations of special centrifuge compounds that are formulated to prevent bacterial growth such as the Rosler ZF compound range. Adding a biocide to the system to prevent bacterial growth. Ensuring that the process water is always in motion by using stirrers or other aeration methods. Reducing the length of time process water is used before replacement. Periodic cleaning of the tanks and piping, especially during a process water change. The Rosler Way When correctly designed, calibrated, and monitored, centrifuge technology can produce water and compound savings of up to 95% while simultaneously delivering precise mass finishing results. Whether you are researching new equipment or troubleshooting an existing process, contact Rosler for assistance and innovative solutions. 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.”