CASTING INNOVATIONS
Metalcaster Revamps Shotblasting Operation, Improves Efficiency In early 2013, Rochester Metal
Products Corp., Rochester, Ind., iden- tified its shotblasting operation as a source for possible improvements. Te existing machine had a magnetic sepa- ration system, but it was outdated and performance continued to fall short of expectations. Rather than install an entire new machine, Rochester Metal Products requested quotes for rebuild- ing and upgrading its current 34-cu.- ft. tumble blast unit. Eventually, the ductile and gray iron metalcaster chose Blast Cleaning Technologies (BCT), New Berlin, Wis., a division of Met- cast, to service its operation. While Rochester Metal Products was shut down during the 2013’s Fourth of July holiday weekend, BCT installed new blast wheels and added improved magnetic separation capabilities to the existing equip- ment. BCT was able to complete the project in three days, meaning the machine was back up and running when production resumed. Tough installation proved to be a logistical challenge thanks to spatial con- straints, Rochester Metals experi- enced immediate benefits. “Although the footprint was a chal-
lenge, and the delivery was pushed, we upgraded to dual e-wheels and magnet-
Shown is the modified upper structure and magnetic separation system assembly.
ic separation,” said Marc Avila, design engineer, Rochester Metal Products. “[We have] reduced cycle time by up to 40%, increased uptime with less wheel maintenance and basically eliminated the need for re-cleaning.” In addition to increased efficiency, the tumble blast machine’s existing double-lip airwash separators were replaced with Metcast High Effi-
ciency Magnetic Separators. Tis installation included a dual
drum system, with primary and secondary magnetic drums. Te HE series Magnetic Separation System is designed to handle heavy sand load- ings and extend the life of blade and wheel parts. Following the replacement, Rochester Metal Products increased the wear life of its parts, while simultane- ously reducing shot consumption. “Te Blast Cleaning Technologies design is a major improvement and saves the life of the magnetic drum. It saves on abrasive consumption, while significantly decreasing the cost of maintenance,” said Avila. “Tis en- hancement to our machine not only has improved production, but the service platforms engineered into the existing equipment design have improved safety and access to the machine.” “A complex project like this
Rochester Metal Products wanted improved performance from its 34-cu.-ft. tumble blast unit.
requires a lot of communication and project planning,” said Craig Wisner, BCT sales manager. “In this case, Rochester Metals, BCT and the installation contractor worked together to make it a successful installation. The turnkey project was a coordinated, well-planned effort that increased efficiency and decreased downtime.”
June 2014 MODERN CASTING | 45
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