Industry: Automotive, Aircraft, and Small Piston Engines
Challenge
A leading manufacturer in the automotive and aerospace industries sought to optimize the etching process for piston rings to prepare them for wear coatings. The challenge was twofold: to reduce part handling and improve processing efficiency, thus lowering operating costs. Previously, the company used a suction-based blasting process that required two separate wet blast systems for handling both the inner diameter (ID) and outer diameter (OD) of the rings, which resulted in increased labor, handling, and transportation costs.
Solution
Empire provided an innovative Cell System that allowed for both ID and OD blasting in a single unit. This solution incorporated a pressure blast system, which was chosen for its superior finish results and efficiency over the older suction and wet blast combination. By integrating the entire blasting process into one system, Empire helped the customer achieve significant operational improvements.
Results
The implementation of the new blasting system resulted in a variety of benefits:
- Reduced Labor Costs: By processing both the ID and OD in the same system, the customer reduced labor costs by up to 25%. The previous process required an additional load and unload cycle, as well as transporting parts between separate wet blast systems.
- Improved Efficiency: The pressure blast system proved more efficient than the previous suction-based process, reducing the total blast time and further lowering production costs.
- Higher Quality Finish: The pressure blast system provided superior finish quality compared to the old process, ensuring better preparation of piston rings for subsequent wear coatings.
Conclusion
By adopting Empire’s advanced Cell System, the customer not only streamlined their production process but also achieved measurable cost savings and enhanced product quality. This single-unit solution eliminated the need for multiple systems and labor-intensive handling, resulting in a faster, more cost-effective, and higher-quality piston ring preparation process.