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.
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:
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.
A number of factors contribute to mass finishing success. Machinery, consumables, compounds, and process water must be evaluated individually and as a whole to create optimal results and stable process conditions.
When considering the flow rate of compound and process water into the processing bowl of a mass finishing machine, careful calibration is required based on the machine type and size, finishing task, condition of the raw work pieces, and process water conditions.
For example, high‐energy machines require a much higher flow rate than vibratory finishing systems. Similarly, work pieces heavily contaminated with oil, grease, and/or dirt require more compound and water than less contaminated work pieces.
Water flow and compound dosing rates are usually determined by processing trials in the test lab of the equipment supplier. Once a finishing process has been defined, the user must make sure that the established water and compound flow parameters are precisely maintained. This requires a well-calibrated and well-maintained dosing system.
At Rosler, we draw upon more than 80 years of worldwide experience to create and maintain effective mass finishing systems and deliver precise results. Our ability to do so is thanks, in part, to understanding the importance of water flow and compound dosing.
Joint reconstruction implants are subject to the same zero-defect performance and reliability standards as any other implant. However, because two components are always interacting with each other, dimensional accuracy is of particular importance.
Within the medical industry, surface finishing experts such as Rosler assist implant manufacturers in achieving the exact finish needed for each surface of the joint.
In addition to increasing product popularity and demand for the manufacturer and providing medical professionals with safe and dependable joint replacements, ensuring that orthopedic implants have the exact finishing required enables the joint to function longer and more comfortably for the patient.
Because of its many technical advantages and versatility, wet blasting is the fastest-growing segment in the field of shot blasting.
As with dry blasting, the available scope of wet blasting machinery ranges from simple, low-cost blast cabinets to sophisticated, partially or fully automated systems. Customers can choose between a wide spectrum of standard wet blasting equipment, however, for certain applications, special custom-engineered systems may offer the most efficient and cost-effective solution.
The machine type is usually determined by the processing task, the size and shape of the work pieces, and the desired degree of automation. Frequently, multi-axis robots are used for work piece handling or guiding the blast gun movement.
Rosler has extensive experience in wet blasting technology and the development of customized solutions. We have even developed the Rosler PureFinish® system for cleaning stainless steel components for the chemical, food, and pharmaceutical industries through wet blasting. This system cleans the work piece surface while facilitating cleaning, sterilization, and prohibiting bacterial growth.
Learn more about common types of wet blasting systems and examples of machine use for a glimpse into the technical capabilities wet blasting offers.
Critical aerospace components require first-class surface treatment. From engines, fuselage, wings, and landing gear to seats, gears, propellers, blades, fasteners and tanks for fuel, water, and waste, Rosler has industry experience and expertise.
While mass finishing and shot blasting methods are equally useful to manufacturers of new components and in the overhaul and repair of existing components, shot peening – a particular type of shot blasting – is especially advantageous for aerospace work pieces thanks to its ability to provide surface finishing and create internal compressive stress for improved component life.
Shot Blasting Capabilities
Rosler’s shot blasting technology meets the strict surface finishing requirements predicated by tight tolerances for safety and longevity. This impact-based process propels small metal or mineral pellets onto a work surface at speeds of 200-800 feet per second.
Desired finishes including cleaning, texturing, removal of or preparation for coating, and peening can be pinpointed to specific areas of a given work piece as well as the entirety of large, structural components.
Achieving the desired surface conditions in a mass finishing process requires the machinery, consumables, compounds, and process water to work together in a balanced manner. Independent of the other process elements, the process water itself must be evaluated for hard and soft water issues.
Rosler has more than six decades of experience designing mass finishing machinery, supplying consumables and compounds, and developing processes. Understanding the ramifications of too hard or too soft process water is a key to our success.
Classifications and Measurements
Depending on its geological source, the water used in mass finishing processes may have varying mineral content levels, specifically calcium and magnesium carbonates, bicarbonates, and sulfates. A high amount of mineral content is used to classify the water as “hard”, whereas low mineral content classifies it as “soft”.
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.
Fueled by more active lifestyles and increased life expectancy,the market for knee, hip, and other replacement body jointsis on the rise. With more than $19 billion in annual worldwidesales, implants for joint reconstruction make up nearly 40 percentof all orthopedic product sales.
Thanks to significant advancements in materials and new or improvedsurface finishing technologies, today’s artificial hips andknees can last more than 20 years, giving the recipient decadesof comfort and agility.
Parts that are finished using modern mass finishingand shot blastingmethods play a key role in extending the lifespan of orthopedic implants.
Rosler has extensive experience in these processes which often include cleaning, deburring/edge radiusing, surface smoothing, post-casting surface preparation, machining, CNC grinding, and, of course, final finishing. These finishing technologies make big differences in the quality and performance of such products.
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.