Frequently Asked Questions

Some performance benefits of Pro-Finish® systems include the ability to achieve consistent surface finish quality, reduced finishing time, increased production rates, and reduced maintenance costs.

“Modified” is Empire’s term for customizing our incredibly durable and productive Pro-Finish® cabinets to meet a customer’s individual work piece or process requirements by blasting either manually or with a certain degree of automation. Modified Pro-Finish® cabinets offer a solution that is affordable and ideally suited for lower production volume environments requiring a robust product. The growth and sophistication that we have seen in this segment have blurred the lines between manual cabinets and automation.

Empire’s modified air blast cabinets can be a solution for unique applications or to improve production rates through partial automation. They can be designed to accommodate a wide range of finishing needs and offer flexibility for handling different work pieces, which can lead to more efficient production processes.

The comfort and ease of use for the operators of our equipment is a priority for our design team. By prioritizing ergonomics, Empire ensures that our customers are able to achieve optimal performance and efficiency from their finishing equipment. Ergonomically designed blasting cabinets can help to reduce fatigue and injury of workers, improve productivity, and enhance the overall user experience.

Yes, Empire’s Ergo-Blast line of air blast cabinets range from our ERGO 2636 to the larger ERGO 6060, which permit blasting of larger work pieces, reduced noise, and a front mounted pressure regulator - all aimed at improving operator comfort and performance during long and repetitive blast cycles. Empire’s Ergo-Blast cabinets focus on operator performance and give manufacturers an edge in many hands-on processes.

Empire’s SEM-2 Cartridge Dust Collector is essential in the removal of toxic particles from the air. The SEM-2 includes a 4” diameter media recovery hose, a 600 cfm externally turntable, cyclonic reclaimer with internal ultra-wear lining, and an 11’ dust hose with a 6” diameter. In addition, a 600 cfm cartridge dust collector (SEM-2) with a 1 ½ hp blower on the clean air side and a HEPA filter on the exit of the SEM-2 blower are also included. These features are essential for safe and effective removal of toxic dust. Furthermore, the electronic timed door interlock ensures that doors cannot be opened until a set time has elapsed after the foot treadle is released, providing an extra layer of safety.

The benefits of automation come from a standpoint of reliability, consistency and repeatability, but now with the challenges in the labor force, this is just adding to the benefits of considering automation solutions with blasting applications. More often we are being asked by our clients to engineer fully automated and robotic air-blast room systems to process large families of parts formerly manually blasted in a room.

Our standard automation solutions include products such as our flexible Cell Machines (CM), Indexing Turntables (TT) and the ever-popular Rotary Head style machines. These machines continue to lead us into projects that one would not readily anticipate the application of such equipment. That’s the trend we are noticing - new applications for existing standard automated equipment.

Customized automation is the reason our engineers stay challenged. Customized automation is not just restricted to aerospace and automotive shot peening applications. Empire has seen remarkable growth in automated grit blasting projects in the Power Generation, Medical, Oil & Gas and such advanced manufacturing sectors. The reasons, as we see them, are several - repeatability, productivity, accuracy, and speed to highlight the most critical on the list. Aerospace customers demanding all the above features in their equipment is quite common, which has now spread to other sectors too. As a result, it is not unusual for us to build grit blasting equipment with closed loop process control for air pressure, media flow, monitoring the condition of blast media, and reporting all these variables in real time, just as it were a peening application.

Empire offers a diverse range of automated systems, including indexing turntable machines, batch processing machines (both continuous and indexing), continuous processing air blast machines, single-piece flow cell machines, rotary head blasting machines, shot peening systems, and in-line air blast systems. These systems range from standard automation to advanced robotic nozzle and part manipulation, catering to a variety of production needs and complexities. Custom systems are also available, tailored to specific customer requirements, incorporating factors such as part size, weight, shape, production rates and material handling.

Automated abrasive blasting systems offer several advantages including increased productivity (with reported gains of 100-700%), improved consistency and repeatability, reduced labor costs, enhanced safety, and the ability to process parts with complex geometries. Automated systems also allow for precise control of process parameters like media flow, air pressure, and speed, ensuring consistent results and reducing rejections. Many automated systems remove the need for manual part manipulation, which leads to greater efficiency. Additionally, they can free operators to perform other essential tasks. Some automated systems such as the TT36-S are designed to do the job of multiple manual machines, optimizing workspace as well.

Indexing turntable machines are designed to automate the blasting process by precisely positioning parts in front of blast nozzles, ensuring consistent treatment. These machines feature a rotating platform with multiple stations where parts are loaded, blasted, and unloaded. This automated approach improves repeatability and process control. They are highly versatile, offering multiple configurations including various table sizes and nozzle options. Loading and unloading can be manual or automated using robotic systems, and can often be done under the cover of blasting to increase efficiency. They are frequently used for applications that require cleaning or shot peening.

The rotary head system uses multiple blast guns mounted on a rotating assembly to deliver consistent coverage, even on parts with irregular shapes. This system allows for uniform blasting by utilizing adjustable mounting arms and media flow regulators. The speed of the rotating head can be adjusted, and the guns can be individually controlled to optimize the blasting process for specific parts. Rotary head systems are often integrated into batch, continuous turntable, and in-line conveyor systems. The use of multiple guns allows for a higher media flow rate and increases overall efficiency, with potentially less energy required for the job.

Batch processing involves loading parts onto a turntable, setting a timer, and then returning once the blasting cycle is completed. This approach is suitable for parts that need longer blast cycles. Continuous processing, on the other hand, allows parts to be continuously loaded and processed, often using a turntable or in-line conveyor system. This is more suitable for high-volume production scenarios, where parts can be continuously fed into the system, often integrated directly into a production line. Continuous systems may include robotic loading and unloading and are available in various sizes.

Shot peening is a controlled blasting process used to induce compressive stress on a component, which is used to improve fatigue resistance and structural integrity. While it uses similar equipment to other blast processes, shot peening is distinguished by its rigorous control of process parameters such as air pressure, media flow rate, media size, and media shape. This is because shot peening is often a process mandated by industry specifications and requires audits and process controls for quality and repeatability of results. Empire provides systems with monitoring and control of variables related to shot peening.

Empire's automated systems incorporate multiple safety features, including light curtains at loading/unloading stations, door safety interlocks, and timed door locks. These features are designed to protect operators from hazards associated with the blasting process, like dust and noise. The timed door lock is an electronic interlock that prevents doors from being opened until a specified time has elapsed after a cycle, allowing for dust to settle before being exposed. Furthermore, Empire systems use a dust collection system which ensures dust is removed safely.

Yes, Empire encourages customers to visit our demonstration lab in Langhorne, PA to test their own parts on a variety of machines. This allows customers to evaluate the expected results and confirm that they are selecting the right equipment for their specific applications. Empire also supports customers with installation, training, technical service, and a global distributor network for local support and parts. We have in-house engineering to accommodate design modifications and are dedicated to using modern controls and electronics.