Foundry
Foundry castings cleaning, Southeast Asia
A foundry in Southeast Asia produces pump housings, valve bodies and impellers for water and process equipment. The castings arrive at the finishing area with sand, burned-on binder and mill scale packed into recesses, and for years the plant cleaned them by hand with wire brushes and abrasive discs. The manual route was slow, depended on the operator and left an uneven surface that reappeared at the painting stage. Several housings have thin walls and flat sealing faces, so a tumble belt was ruled out: parts would strike one another and the gasket faces could be marked. The foundry needed a batch process that could handle a mixed range of shapes without part-to-part contact. Production runs in campaigns, so the batch mix changes from large pump housings to smaller valve bodies within the same shift, and the cleaning cell has to absorb that variation without a separate setup for every size.
The application review pointed to a Q37 hanger type shot blasting machine. Each casting is loaded on a hook, so the blast stream reaches the outer walls, flanges and open recesses while the parts stay separated. The largest housing and the longest impeller were used to define the chamber and hook height, and the existing crane in the finishing bay set the loading position. Hook loads were limited to 800 kg, with typical batches between 500 and 800 kg. The Q37 range is published at 1.0–2.0 t/h for this envelope, and the plant runs the line at 1.2 t/h. The loading station was laid out so the crane drops a casting directly onto the hook and the operator can check the fixture before the door closes; a second hook position is kept free for changeovers.
The configuration uses the standard Q37 blast wheel arrangement, with an abrasive separator that removes broken shot and dust before the media returns to the wheels. Dust is drawn from the chamber through a filter, and the extraction duct was connected to the foundry ventilation route. The hook positions were arranged so the blast stream sees the main faces and the open cores. Blind pockets and deep internal passages are still touched up by hand; this was agreed during the review instead of being discovered after commissioning. The operator loads a batch, closes the door, selects the recipe and unloads into stillages. The extraction was balanced inside the machine 5000–16000 m³/h range, and the shot size was selected for cast iron rather than a generic mix. The chamber door is interlocked with the wheel drive so the cycle cannot start with the door open.
At 1.2 t/h a typical 600–800 kg batch takes about 35–40 minutes, including loading and unloading. The machine runs across two shifts, and the plant keeps a reference casting for the daily surface check. Exposed surfaces reach SA 2.5, and the painting line now receives a consistent surface instead of a mix of hand-cleaned patches. Delivery covered the foundation, the connection to the dust collector, commissioning with production castings and operator training. A recommended wear-part list is kept on site so a worn blade or liner does not interrupt the batch schedule. Safety interlocks and a daily walk-around are part of the shift routine, and the maintenance check covers the wheel blades, chamber liners and separator screen. The plant keeps a simple log of blasting time and surface result for each campaign.
Country / region: Southeast Asia
Read case studySteel pipe manufacturing
Steel pipe surface preparation, Middle East
A pipe mill in the Middle East produces large-diameter longitudinal seam pipes for water transmission and structural projects. The external coating line needs a clean, uniformly profiled steel surface, but the plant was relying on manual blasting and spot repair. Mill scale and rust varied along each 6–12 m section, and the coating team was rejecting sections where the surface still carried shadowed patches. The pipes weigh between 5 and 18 t and cannot be turned by hand, so the cleaning step also had to fit the existing roller handling without adding a crane operation. Coating thickness and adhesion depend on the profile, so a pipe that fails the surface check is sent back before coating rather than patched afterwards. The mill also runs campaigns of different diameters, and the cleaning cell has to switch recipes without a long mechanical change.
The Q69 roller conveyor shot blasting machine was selected for the pass-through layout. Pipes are carried on powered rollers through the blast zone and turned by the rollers as they travel, so the full circumference sees the blast stream. The published Q69 range covers 2.0–5.0 t/h and workpieces from 5 to 30 t, which matches the mill pipe sizes. The line runs at 3.2 t/h. The machine sits between the existing transfer table and the coating line, so a pipe moves from the yard to blasting and then to coating without being lifted out of the roller path. The roller line was lengthened to match the longest pipe, and the entry and exit tables were aligned with the yard conveyor.
The configuration has four 11 kW blast wheels arranged around the roller path. Roller pitch and line speed were set so each pipe receives the exposure needed for SA 2.5, and the wheels can be adjusted when the mill switches to a different wall thickness or diameter. Abrasive is recovered from the chamber floor, separated from scale and dust, and returned to the wheels. The dust collector was sized for the existing extraction header, and the discharge end was fitted with a short transfer roller section so the coating line can take the pipe at its own pace. The operator station shows the selected recipe and the line speed. Roller drives are monitored for slip so a pipe does not stall in the chamber, and the discharge section keeps the pipe clear of the blast zone before it reaches the coating crew. The chamber is sized around the largest pipe diameter in the current product range.
At 3.2 t/h the mill processes roughly 25 t in an eight-hour shift, depending on pipe length and handling time. The coating team checks the surface against a reference section before each campaign, and the line keeps a spare set of wear plates and blades on site. Delivery included the roller foundation, alignment with the existing transfer table, commissioning on production pipes and training for the line operators. The mill can now blast and coat in one continuous route instead of batching pipes for manual repair. Operators were trained on recipe changes and on the daily inspection of the rollers, and a spare roller and a set of wear plates are kept in the mill store.
Country / region: Middle East
Read case studySteel fabrication
Structural steel cleaning, East China
A steel fabrication plant in East China builds welded beams, columns and plate assemblies for industrial buildings. The shop receives mill scale, rust and welding residue on parts that can be up to 12 m long and weigh between 8 and 22 t. Cleaning was done at the paint line with hand grinders and spot blasting, which left a patchy surface and slowed the coating crew. The plant wanted a through-feed solution that could sit before the painting booth and handle the same lifts already used in the bay. The shop works to a weekly painting programme, so parts often wait in the yard and pick up surface rust before they reach the booth. Some assemblies are too wide for a small cabinet and too heavy for a turntable, which is why the manual route kept coming back to grinders.
A Q69 roller conveyor machine was arranged as a pass-through unit ahead of the paint line. The published range covers workpieces from 5 to 30 t and 2.0–5.0 t/h, so the largest welded column fits within the roller loading. The line is set to 4.0 t/h for the current mix. Beams are loaded by the existing overhead crane, travel on powered rollers and leave the chamber ready for masking and painting. No extra transfer crane was needed. The line was laid out so the crane can load at the entry end and unload at the exit without crossing the blast zone, and the published roller width and weight range were checked against the widest base plate in the shop.
Four 11 kW blast wheels are positioned above and below the roller path, and the roller speed is set from the beam section and the required surface. The chamber has replaceable wear liners, and the abrasive recovery system separates scale and dust before returning shot to the wheels. Dust extraction is connected to the shop filter unit, and the outlet was coordinated with the paint booth extract so the two systems do not fight each other. The recipe list covers plates, H-beams and box sections, and the operator selects the section type before loading. The roller drives are inverter-controlled, so the line can be slowed for a heavy column without changing the blast settings. Abrasive consumption is checked weekly, and the separator is cleaned at the same interval.
At 4.0 t/h a 12 m beam section moves through in a few minutes, and the shop schedules blasting and painting in the same shift. The paint team checks the surface and the profile on a reference beam at the start of each batch. The plant notes fewer spot repairs before coating, although the acceptance decision remains with the coating inspector. Delivery included foundation work, roller alignment with the existing line, commissioning on production beams and operator training. Wear liners and blades are stocked according to the recommended list. The paint booth extract was balanced after commissioning so blast dust does not migrate into the coating area. Records of line speed and surface result are kept with the painting programme, and safety guards cover the entry and exit roller sections while the maintenance team inspects the line stopped.
Country / region: East China
Read case studyRailway maintenance
Railway maintenance parts, North Africa
A railway maintenance base in North Africa overhauls freight wagon components. Brake blocks, coupler pins, axle box covers and other small steel parts arrive with rust, old paint and grease, and the depot used wire brushes and angle grinders to prepare them for inspection and recoating. The volume is high but the parts are small, and the manual method was creating a bottleneck before the reassembly benches. The parts must not be damaged by heavy impacts, and the depot needed a batch process that could be run by the existing team. The depot handles a steady flow of worn parts from the wagon overhaul line, and every part has to be ready for inspection on the same day it is stripped. Grease and old paint also hid cracks that the inspection team needed to see.
A Q32 tumble belt shot blasting machine was selected. The rubber belt accepts batches up to 120 kg and individual parts up to 2 kg, which covers the depot component range. The published throughput is 0.6–1.2 t/h, and the depot runs at 0.8 t/h. The machine is loaded by placing a batch in the belt, and the tumbling action exposes all sides of the small parts without manual handling. Threaded or precision parts are reviewed separately and are not mixed into the same batch. The batch size was matched to the stillage used at the benches so parts do not have to be re-counted after blasting, and the rubber belt and the low drop height reduce the risk of bent or chipped parts.
The Q32 uses a rubber belt that is gentler on painted or machined surfaces than a steel belt. The blast wheel, separator and dust filter are sized for the batch load, and the extraction is connected to the depot workshop ventilation. A pre-wash removes loose grease before blasting, because shot alone does not remove oil. The operator selects the batch recipe, monitors the ammeter and unloads into a container at the discharge end. The machine footprint fits the existing bay without blocking the inspection benches. The pre-wash tank was sized for one batch at a time so the blasting cycle is not waiting for parts to dry, and the dust filter is cleaned on a weekly schedule while the separator screen is checked for wear.
At 0.8 t/h a 90–110 kg batch takes roughly 8–10 minutes of blasting, plus loading and unloading. The depot runs several batches per shift and keeps a reference part for the surface check. Accessible surfaces reach SA 2.5, and the reassembly team receives parts without the patches left by hand tools. Delivery included the foundation, the pre-wash connection, commissioning with depot components and training. Spare belts and wear parts are kept at the base so the maintenance schedule does not depend on a long delivery. The depot logs the batch weight, blasting time and surface result so the overhaul file can be completed. The machine is stopped and locked for belt inspection, and the maintenance team follows a checklist that covers the drive, belt tracking and the dust filter.
Country / region: North Africa
Read case studyAutomotive components
Automotive parts cleaning, South America
An automotive component supplier in South America produces brackets, stampings and suspension parts for an e-coating line. The parts arrive with stamping scale and light rust, and the plant previously cleaned them in batches. Flat brackets nested in the batch, so some faces were shielded and others were marked by contact. The coating line needs a consistent surface on every part, and the supplier wanted a continuous process that could run at the line takt rather than a batch cycle. The supplier runs several part families on the same line, and the cleaning step has to change over without stopping the e-coat line for long.
A QWD800 mesh belt shot blasting machine was chosen for continuous handling. The through opening is 800 × 500 mm and the conveying speed range is 0.5–4 m/min, which suits the bracket sizes and the line rhythm. Published throughput is 1.0–3.0 t/h, and the line runs at 2.4 t/h. Parts are spread on the mesh belt and pass through the blast zone without fixtures, then discharge onto the existing conveyor. The machine was placed between the press cell and the e-coat loading station. The mesh belt was selected over a roller conveyor because small brackets would fall between rollers, and the belt width and opening were checked against the widest suspension bracket. The machine footprint allowed the existing fork-lift route to stay open.
The belt speed is set at 1.8 m/min for the current mix. Parts are loaded in a single layer so each face sees the blast stream, and the review identified a small group of parts that need a second pass because of their shape. The dust collector is rated at 12000 m³/h and is connected to the belt chamber, and the abrasive recovery system returns shot after separating dust and fines. The operator checks the belt loading and the discharge before each shift. The loading crew uses a simple gauge at the entry to keep parts inside the opening, and the exit chute was adjusted so parts do not drop onto each other. The blast wheels are checked for blade wear every maintenance window, and the mesh belt is inspected for tracking and tears.
At 2.4 t/h the line keeps pace with the press cell and the e-coat line without building a buffer. The supplier checks a reference bracket for surface and profile at the start of each run. The continuous flow removed the nesting problem, and the flat faces now reach the coating stage without contact marks. Delivery included the belt foundation, the interface with the existing conveyors, commissioning on production parts and operator training. Wear parts and belt tracking are included in the preventive maintenance plan. Changeover between part families is handled by the recipe list, and the first parts of a new run are checked before the line speed is released. The supplier also keeps a spare mesh belt on site because a torn belt would stop the line. The installation was commissioned during a planned shutdown so production restarted on schedule, and operators were trained on belt loading, emergency stops and daily checks.
Country / region: South America
Read case studyAerospace components
Aerospace components preparation, Europe
An aerospace component supplier in Europe machines brackets, housings and support parts from aluminium and titanium alloys. The parts are high value and small enough to handle on hooks, but they cannot be tumbled or allowed to contact one another. The previous cleaning method was a manual cabinet, and the results varied with operator technique, especially around edges and machined pockets. The supplier needed a controlled batch process with predictable coverage and a clear loading arrangement for each part family. The parts are inspected after blasting, and any embedded media or damaged edge would be a reject, so the process had to be repeatable rather than merely fast. The supplier also needed a loading arrangement that could be documented for its own process control.
A Q37 hanger type machine was selected because each part can be suspended individually. Hook loads are kept at or below 600 kg, and typical batches are 300–500 kg. The published Q37 throughput is 1.0–2.0 t/h, and the cell runs at 1.0 t/h. The chamber and hook height were set around the largest housing, and the existing overhead crane serves the loading station. The machine sits in a finishing cell with access for masking and inspection before and after blasting. Individual hooks were made for the main part families so a bracket cannot swing into a neighbour during the cycle. The hook height was set so an operator can mask a part at bench level before lifting it.
The abrasive is selected for the alloy and the required finish, and the supplier confirmed media compatibility before commissioning. Critical surfaces are masked, and the hook positions are arranged so the blast stream reaches the faces that need preparation without over-processing thin sections. Dust is extracted through a filter, and the abrasive separator removes fines before the media returns to the wheel. The recipe records the wheel setting, the blast time and the hook position for each part family. The supplier wrote the recipe set with the process team, and each recipe is locked to a part number so an operator cannot change the blast time by accident. Masking plugs are reused and checked before each batch, and the inspection step after blasting includes a visual check for remaining masking.
At 1.0 t/h a 400 kg batch takes roughly 24 minutes of blasting, plus masking and inspection. The cell runs to the production schedule and keeps a reference part for the daily check. Accessible surfaces reach SA 2.5, and the inspection team receives parts with a repeatable surface instead of a manual patchwork. Delivery included foundations, the dust connection, commissioning with production parts, operator training and a documented recipe set. The supplier keeps a spare set of blades and liners so a wear change does not interrupt the cell. The cell is cleaned between families to avoid cross-contamination of different alloys, and the dust filter is monitored for pressure drop. The training covered loading, masking, recipe selection and emergency stop, and the supplier keeps a maintenance log for the wheel and the separator. Commissioning was done with production parts, and the first batches were inspected before the cell was released to the shop.
Country / region: Europe
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