Retrofit of blasting systems - higher blasting performance thanks to new turbines

A manufacturer of saw blades invested in new turbines for a continuous belt blasting system. The retrofit increased the blasting performance by 25 % while at the same time significantly reducing energy consumption.

A reliable spare parts supply and higher blast performance were the decisive factors for a manufacturer of band saw blades to invest in modern turbine technology for a continuous belt blast machine. The choice of the high-performance Rutten Gamma 330-HD turbines from Rösler was due on the one hand to their extremely wear-resistant design. On the other hand, they offer a 25 % higher blasting performance with significantly lower energy consumption. The company is now planning to equip further blast machines with these blast turbines.

The band saw blade manufacturer's products are used worldwide in markets where precision and quality, such as edge accuracy or flatness, define the value of semi-finished steel strip products. In order to meet these high quality standards, the entire production takes place in Germany despite the export share of around 90%. The production steps include a blasting process with a continuous strip blasting system.

The system from a southern European manufacturer used for this blasting process was to be optimized. The employee responsible for improvements in system operation therefore contacted Rösler during a visit to the Deburring Expo. In addition to a reliable supply of spare parts and the desired service, the discussion focused on increasing the blasting performance to increase throughput. Based on the process data provided, the blasting system manufacturer drew up a concept and offer for retrofitting the turbine technology. This included equipping the existing system with two Rutten Gamma 330-HD high-performance turbines with 7.5 kW each, which corresponds to the output of the previous turbines. The suitability of the turbines on offer was underpinned by blast tests with the company's components at Rösler's Customer Experience Center.

The performance of the Rutten Gamma turbines is based on their design. They have four Y-shaped throwing blades with a precisely calculated angle of curvature. This ensures precise abrasive discharge at maximum discharge speed and therefore significantly improved efficiency compared to conventional turbines. In the existing system of the band saw blade manufacturer, an increase in blasting performance of around 25 % was achieved, making it easy to implement the desire to increase capacity. In addition, the efficient blast media delivery enables energy savings of up to 25 percent. The throwing blades are made of a highly wear-resistant alloy and can be used on both sides. The Rutten high-performance turbines therefore achieve a 10 to 16 times longer service life, depending on the abrasive used. In combination with the reliable and fast supply of spare parts by Rösler, this contributes to a high, assured system availability and at the same time reduces maintenance costs.

The replacement of the turbines on the existing third-party blast machine was carried out in a comparatively short time, as no conversion work was required apart from minor adjustments to the mounting flange. Parallel to the turbine replacement, the company's maintenance team adapted the machine to the improved blasting performance in consultation with Rösler. For example, the blast chamber was fitted with additional wear protection plates.

After around a year of operation, the manufacturer of band saw blades is so impressed with the Rutten high-performance turbines that further blast machines from the southern European manufacturer are to be modernized accordingly. (OM-2/26)