Empire’s automated abrasive blast systems enhance productivity through several key features and design elements. Customers have reported productivity gains between 100 and 700 percent when using these automated systems compared to manual methods. Here’s how these systems achieve such improvements:
- Reduced Manual Labor: Automation reduces the need for manual labor, minimizing occupational stresses by eliminating the need for workers to manipulate workpieces or manually blast them. This allows employees to focus on other essential tasks. For instance, the RS-6060 batch processing system requires only minimal operator interaction, with the operator simply loading the workpiece, starting the cycle, and returning after it is completed. In some cases, one operator can monitor multiple automated machines at the same time.
- Increased Speed and Efficiency: Automated systems are designed to operate with a high level of efficiency, with robotic systems being programmable for loading materials, commencing blasting, and completing the process with a quick turnaround time. The indexing turntable machines provide precise positioning of the workpiece in front of the blast nozzles, ensuring consistent and repeatable processing.
- Consistent Quality: Automated systems provide a more consistent and reliable process. For example, rotary head systems deliver uniform blasting, which is especially beneficial for parts with complex geometries. The consistency of these systems also leads to fewer rejected parts.
- Optimized Cycle Times: Systems like the TT-20 indexing turntable have smaller turntables for faster cycle times. Batch processing systems can be set with timers that allow operators to complete other tasks while the machine is running. Additionally, continuous processing machines allow for parts to be loaded and unloaded without stopping the blast cycle.
- Reduced Per-Unit Costs: Automated systems reduce per-unit cleaning costs. For example, an indexing turntable machine reduced per-unit cleaning costs on piston rebuilds by more than 30% compared to previous methods.
- Space Optimization: Automated systems like the TT36-S indexing turntable system can do the job of multiple manual blast cabinet machines, optimizing workspace and providing a cost savings. The versatility of rotary heads combined with automation allows facilities to lower their operational footprint by as much as 50%.
- Customization: Empire’s custom automated systems can be engineered to fit a specific process and production requirements to maximize efficiency.
- Media Recovery: Empire blast systems are equipped with a proprietary dust collector for optimum media recovery and cabinet ventilation.
- Advanced Controls: Empire systems come with advanced controls, which may include media flow controls, air pressure controls, speed controls and media recovery systems. These controls provide the means for process validation and reporting.
- Rotary Heads: Rotary head systems contribute to higher productivity due to multiple blast guns. They also provide consistent and precise blasting of complex parts.
- In-Line Systems: In-line belt conveyor systems reduce manual operation by providing a continuous flow of workpieces down the production line.
By implementing automation, companies can achieve increased productivity, reduced per-unit costs, improved consistency, and a safer working environment. Automation allows operators to focus on other essential tasks, optimizing the overall manufacturing process. For instance, an automated system like the TT36-S indexing turntable can replace multiple manual blast cabinets, optimizing workspace and reducing labor.