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.
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: