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?
Continue reading Optimized Finishing Processes Can Reduce Operational Costs
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
Continue reading Centrifuge technology offers eco-friendly advantages
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.
Continue reading Mass Finishing 101
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.
Waste water from mass finishing applications is often referred to as effluent and must be cleaned for recycling or discharge.
Continue reading Centrifuge Technology Processes Effluent for Reuse and Disposal
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
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.
Continue reading 8 Considerations When Purchasing a Rotary Vibratory 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.
Continue reading THE 9 MOST COMMON MISTAKES YOU NEED TO AVOID TO GET THE MOST OUT OF YOUR MASS FINISHING MACHINE
Vibratory finishing systems are best known for treating large volumes of mass produced parts. However, thanks to a variety of new, innovative equipment designs, they are increasingly utilized for finishing single work pieces with highly complex geometries.
An excellent example of this new equipment design is Rosler’s model R150/2 DL. A rotary vibrator without an inner dome, this unique finishing process allows for work pieces to be bolted to the vibratory processing bowl.
Continue reading New Vibratory System Design Accommodates Complex Shapes
Tip #3 – Optimum operating conditions
Once a mass finishing process has been established by the selection of machine, media and compound, the system must be constantly monitored and, of course, properly maintained. The good news is, this is quite easy! By following a few simple quality control rules, the process will remain absolutely stable, producing the desired finishing results for many years:
Read more about optimum operating conditions
Tip #2 – The need for processing trials
Of course, the selection of the right machine, media and compound can sometimes be a bit intimidating. Not only does a mass finishing user have to choose among a wide variety of machine types and sizes, they must also pick the right media from hundreds of media types, shapes and sizes. And on top of all this Read more about processing trials