Case Study: Enhancing Surface Finishing for Sign and Tile Manufacturing with the Empire 6060RS Rotary Head System

custom rotary head air blast systemBackground: A customer in the sign and tile manufacturing industry required a solution to process flat parts with uniform surface coverage and consistent blast intensity. The challenge was to ensure that both the inside and outside diameters of the table surface received even treatment. Empire’s standard 6060RS Rotary Head System, with its rotary head oscillation, provided a strong foundation, but an additional movement was needed to meet this precise requirement.

Solution: To address the customer’s needs, Empire enhanced the standard 6060RS Rotary Head System by integrating a horizontal oscillating motion. This modification allowed the rotating suction guns to evenly cover the entire surface, from the inner to outer diameters, ensuring uniform blast coverage and intensity across the flat parts. The improved machine included the following features:

  • Horizontal Oscillation: The addition of this movement to the rotary head ensured consistent surface treatment, eliminating gaps or inconsistent blast patterns.
  • 12” Rotary Head Oscillator: Outfitted with six suction guns, this system was designed to maximize coverage over the entire part surface.
  • Variable Control: Adjustable speed settings for head rotation, table speed, and horizontal oscillation allowed the operator to finely tune the process for precise finishing.
  • Nozzle Angle and Clearance Adjustability: These features enabled further customization of the blasting process, offering greater control over the surface finish.

Operational Efficiency: The redesigned system also provided several ergonomic and efficiency improvements:

  • Large Vertical Sliding Door: The door offered a wide loading area, facilitating quick part changeovers and reducing operator fatigue.
  • Advanced Dust Collection System: Empire’s EM2-2 series cartridge dust collector was included, featuring Photohelic pulse cleaning controls. This “state-of-the-art” system ensured superior dust collection performance in harsh environments, reducing airborne particles and maintaining a cleaner work environment.
  • Media Makeup Hopper: Designed to reduce operator involvement during the blasting process, the hopper automatically replenished media, allowing for smoother operation and fewer interruptions.

Model CTT53-RS with Optional Safety Ladder & Railing for Maintenance AccessResults: The customer gained full control over all process variables, ensuring that each flat part received a uniform finish, regardless of size or complexity. By adjusting head rotation, table speed, and oscillation rates, the system delivered superior surface finishing results. The enhancements to the system, combined with the advanced dust collection and automated media makeup, led to significant improvements in operator efficiency and reduced fatigue.

In the end, Empire’s tailored solution exceeded the customer’s expectations, providing consistent, high-quality finishes while streamlining the operational workflow for sign and tile manufacturing.

The 6060RS Rotary Head System with horizontal oscillation has proven to be a powerful and flexible tool for industries requiring precise and uniform surface etching, making it an ideal choice for manufacturers looking to improve efficiency and product quality.