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Improved Productivity – Not Just for Shot Peening. Generally speaking, it is difficult, if not impossible, to improve the productivity and energy efficiency of conventional shot peening machines. One solution to this dilemma is to upgrade existing shot peening machines with Rösler Long Life blast turbines, which will increase productivity and help to significantly reduce operating and maintenance costs. When it comes to increasing uptime, productivity, quality of peening results or energy consumption requirements, most shot peening machines in the field are unable to meet these requirements or can only do so at a very high initial cost. Rösler’s TuneUp department specializes in upgrading shot peening machines of all brands and offers a variety of solutions to optimize the equipment according to customer requirements. Increased productivity and process stability, reduced equipment wear OSK-Kiefer GmbH, with six locations in Germany, specializes in subcontractor shot peening. The renowned workshop’s customers include leading manufacturers of cars, trucks, aircraft, agricultural equipment, transmissions, transmission components, pumps, compressors, gas and steam turbines. At its plant in Petershausen, the company operates several blasting systems with blasting turbines. Plant manager Rudolf Schickinger explains: “The turbines on our blasting machines were somewhat outdated; at the same time, new customer requirements required the installation of new turbines with higher performance, better wear properties and higher energy efficiency.” It was decided to equip three blasting systems with Rösler Long Life Y 330 blasting turbines, each with an installed power of 7.5 kW. Key factors in this decision were the 30% improvement in blasting performance and a service life of more than 10,000 hours for the abrasive blades. OSK-Kiefer uses circular blasting in its shot peening machines. It is worth noting that these blasting cloths, made of hard metal, are resistant to very abrasive abrasive media (e.g. sand with a hardness of up to 64 HRC). Users of older turbines are faced with very low uptimes when working with such aggressive media, and frequent replacement of wear components constantly interrupts work. Rudolf Schickinger sums up his experience with the new turbine: “With the Y 330 turbine, we not only achieved the planned increase in performance, but also actually retained a significant power reserve. Moreover, after about 12 years of operation, we hardly noticed any wear. Of course, this also helps to reduce the amount of maintenance work. Another important aspect is the improved process stability when using our older turbines. The gradual wear of the blades required frequent adjustments. Now the blasting parameters remain constant, which is a huge improvement. Rösler’s “TuneUp” is a tailor-made solution for a wide range of blasting equipment, designed to suit your needs and enabling the modernisation of blasting machines of all makes and designs. The recently launched Gamma-G energy-saving turbine series is another important addition to Rösler’s turbine portfolio. It combines the technical advantages of the Rutten turbine, extremely high stroke speeds and resulting shorter cycle times, as well as a lower purchase price. The German Federal Office for Economics and Export (BAFA) subsidises investment costs of up to 30% for the modernisation of blasting machines through the use of energy-saving components such as IE03 drives. In addition, Rösler offers the possibility of testing the turbine on site beforehand, which virtually eliminates any risk for the customer. With every offer, customers receive an operating cost analysis, which guarantees complete investment security. But TuneUp goes beyond this: Rösler also optimizes the overall wear protection, the abrasive replenishment system and the cleaning systems in the blasting machine. For example, high-performance magnetic separators are installed in the foundry to reduce the amount of residual sand in the abrasive blasting medium. MAX-IMP: Automatic control of the blasting mode With the patented MAX-IMP system, TuneUp also offers an elegant solution for automatic control of the blasting mode. During the blasting process, special sensors installed directly in front of the blast turbine are moved to the hot spots to measure the blast flow. The measurement results are analyzed by a special electronic controller and displayed within a few seconds. This elegant, extremely easy-to-use system replaces the traditional, time-consuming and subjective manual control of the blasting mode, increasing machine uptime, reducing operating costs and improving process stability.