Optimized Finishing Processes Can Reduce Operational Costs

You don’t throw your media out with the waste water, so why would you purchase new mass finishing equipment or muddle through with an inefficient process when optimization can extend the life and enhance the effectiveness of your processing equipment?

Whether a result of increased production needs or in response to poor performance, optimizing your mass finishing process is a great way to reduce operational costs and lower your equipment’s total cost of ownership.

A Proactive Approach

Revising a process to meet increased production demand is a cost-effective way to not only improve your processing times and results, but also increase and prolong your equipment’s usefulness.

Let’s say production has been steadily building over time. How do you know if it’s time to evaluate the process?

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Surface Finishing Guidebook for Medical Instruments

Among the various technologies used for finishing the surface of medical instruments, mass finishing and shot blasting play a key role, not only as intermediate steps but also for placing the final, finishing touch on these components.

Besides the right material selection, surface treatment is an essential component of the overall manufacturing process of medical instruments. Only high-quality surface finishes guarantee the required functionality, high sterility, corrosion resistance, and absolute reliability that most medical components require, while also providing a satin, non-glare appearance.

To cover this complex topic, we’ve created an exclusive surface finishing guidebook, specifically for medical instruments!  In this guidebook we will discuss Continue reading Surface Finishing Guidebook for Medical Instruments

Shot Blasting 101

Shot blasting is a specialized surface finishing process where small metal (or mineral) pellets, called blast media, are thrown onto the surface of a work piece at incredibly high speeds, ranging from 200-800 feet per second.  The impact on the work pieces from this process is what produces the desired surface finishing effect.

Shot blasting can help achieve surface cleaning, surface preparation, descaling, deburring, deflashing, and shot peening.

The process components of a shot blasting system include a shot blast machine, raw and finished work pieces, blast media, dust, and other byproducts.

The two most common types of shot blast machines are turbine blasting and air blasting.

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Centrifuge technology offers eco-friendly advantages

The mass finishing process creates waste water. This substance known as effluent must be properly processed for reuse or disposal. Centrifuge technology offers solutions for cleaning and/or recycling effluent.

Rosler offers a variety of options to process waste water including flocculation systems and the elimination of vibratory finishing sludge. Each type of waste has unique factors and considerations.

Flocculants for Water Circulation Systems

floc graph

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Mass Finishing 101

Often overlooked in the manufacturing process, mass finishing can help add value in a variety of ways.  Mass finishing can reduce or eliminate manual process steps, improve process consistency, increase throughput, reduce manual labor, and more.

Manufacturing or process engineers in a manufacturing plant do not have to be the expert that knows all the latest details and techniques of the finishing process. They do, however, need to have a good understanding of the basic mass finishing processes that can be applied.

Mass finishing describes a surface finishing method where parts are deburred, smoothed, polished, or cleaned using media (tumbling or vibratory), compounds (finishing soap), and specialized equipment.

Examples of mass finishing equipment include:

Understanding how the different process components, i.e. the machine, media, compound, water, and the incoming part all interact and influence the desired part finish is important. Each of the inputs in itself has a multitude of adjustments and parameters.

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Centrifuge Technology Processes Effluent for Reuse and Disposal

In order to achieve the lowest total cost of ownership and the greatest process efficiency, recycling process water used in mass finishing processes is key. Reusing water not only reduces costs in the form of less consumables used, but also enables companies to reduce their discharge and disposal fees by replacing process water less often and complying with water and waste regulations.pollutant table

Waste water from mass finishing applications is often referred to as effluent and must be cleaned for recycling or discharge.

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Waste Water Recycling – Centrifuge Technology Offers Cost, Environmental Savings

Mass finishing techniques are often used to uniformly prepare and finish work-pieces, but the compounds and liquids used to remove fines and other debris from work-pieces must be dealt with to ensure a repeatable process application. Cleaning and/or recycling waste water produced in the mass finishing process is easily achieved with centrifuge technology and provides opportunities to be more environmentally responsible and save money in the form of reduced labor and materials (cleaning agents and compounds).

How Centrifuges Work

In a centrifuge, waste materials including media and metal fines are often referred to as effluent. The effluent to be cleaned either flows directly from the mass finishing system Continue reading Waste Water Recycling – Centrifuge Technology Offers Cost, Environmental Savings

Blast Media – Considerations when choosing

Important factors that should be considered in the selection of any blast media for a particular application is the material and chemical composition, hardness, density, shape, screen size, and, last but not least, the hardness of the component to be blasted.

Component image

The term ‘media’ as used in mechanical surface finishing refers to the free flow abrasive or non-abrasive type of media which carries out the process required on the component.

So, what can be considered and used as a blast media?

Anything! That can be projected through a blasting system.

Media Characteristics to be considered include:

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8 Considerations When Purchasing a Rotary Vibratory Machine

Buying Mass Finishing equipment, as with all investments, can be a bit overwhelming at first.   There will surely be a number of suppliers and machine types available to you.  In order to ensure you get the best value for your money we recommend you consider the following when purchasing a rotary vibratory machine:

Movement– Appearances can be deceiving, don’t be fooled into thinking all machines are the same just because the look similar.  Always test the machine and its processing ability before you buy!  Test its amplitude, see how regular the movement is, is it consistently driving the same way?

Strength and durability – Check how heavy the machine is, usually you’ll find something costs less because it is made of cheaper and lighter materials.

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THE 9 MOST COMMON MISTAKES YOU NEED TO AVOID TO GET THE MOST OUT OF YOUR MASS FINISHING MACHINE

When maintained properly, mass finishing equipment can be very user friendly.

As a result sometimes operators can get into the habit of just turning them on each day and ignoring simple operating and maintenance rules.  Avoiding the following 9 mistakes that operators commonly make will help you get the most from your equipment:

  • They let the media level drop, often with the aim of saving money or so they can get more work pieces in. This changes the ratio of work pieces per media though and can affect process times, unloading ability, can cause components to damage each other, and can result in the required finish not being achievable.

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Shot Blasting and Mass Finishing Surface Finishing Experts

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