Tailor-Made Shot Blasting Machine Doubled Production Capacity
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Client:
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Year of Implementation:
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Location:
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Technical specification:
- Suspension hook dimensions -
H 1000 mm x Ø 800 mm - Maximum hook load capacity - 100 kg
- 6x 7.5 kW blasting turbines
- Carousel-type shot blasting machine
with three chambers - Welded manganese steel chambers
with manganese steel lining - Continuous abrasive flow regulation
with automatic control - Automatic replenishment of blasting media from an auxiliary hopper
- Sorbent dosing unit for removal
of grease from abrasive - Custom-designed machine construction tailored to customer requirements
- Suspension hook dimensions -
-
Client:
-
Year of Implementation:
-
Location:
-
Technical specification:
- Suspension hook dimensions - H 1000 mm x Ø 800 mm
- Maximum hook load capacity - 100 kg
- 6x 7.5 kW blasting turbines
- Carousel-type shot blasting machine with three chambers
- Welded manganese steel chambers with manganese steel lining
- Continuous abrasive flow regulation with automatic control
- Automatic replenishment of blasting media from an auxiliary hopper
- Sorbent dosing unit for removal of grease from abrasive
- Custom-designed machine construction tailored to customer requirements
TECHNICAL DESCRIPTION OF THE INSTALLATION
New Shot Blasting Machine Modernises Surface Treatment
and Doubles Production Capacity
New Shot Blasting Machine Modernises Surface Treatment and Doubles Production Capacity
Every production upgrade begins with the same question: How can we increase output while simultaneously reducing costs? This was precisely the challenge faced by
DGF a.s., a manufacturer of steel gas cartridges — and
our installation proved to be the right solution. The company already operated a
shot blasting machine. However, the limitation was not the blasting quality itself, but the overall process throughput. The machine design we engineered — developed specifically to meet the customer’s requirements — delivered not only a significantly shorter cycle time, but also additional operational benefits that enabled optimisation of the entire cartridge production process. How was this achieved?
Unique Machine Design Optimises Operational Cycle Times
The key improvement lies in the fundamental design of the
blasting machine. The original chamber-type machine was replaced with a carousel shot blasting machine featuring three chambers for efficient surface treatment of steel components. This eliminated the need for conventional part loading and door-based chamber sealing — the chamber is sealed simply by rotation. The
suspension hooks are integrated directly into the machine structure, removing time-consuming handling associated with inserting and loading hook assemblies into the chamber. In practice, one chamber is actively blasting, the second is prepared for loading, and the third simultaneously allows removal of already blasted cartridges. The process therefore runs continuously, without unnecessary downtime.
What does this mean in measurable terms?
On the original equipment, the complete blasting cycle took 10 minutes — 6 minutes of blasting and 4 minutes for opening the chamber, removing the suspension hook assembly, loading a new batch and resealing. The new solution reduced the entire process to just 4 minutes and 20 seconds — 4 minutes of blasting and only 20 seconds required for opening and resealing the chamber. The process time was therefore reduced by more than half, effectively doubling the overall production capacity.
Reduced Blasting Cost While Maintaining Operating Costs
The shortened blasting cycle is not the only benefit of the modernisation. The new machine maintains approximately the same footprint, allowing seamless integration into the existing production line without the need for structural modifications. Operating costs remain at a level comparable to the original equipment. Thanks to the significantly higher throughput, the system processes up to twice as many components within the same floor space. As a result, the blasting cost per unit is reduced by approximately 50%. By modernising its shot blasting process, DGF a.s. successfully increased productivity and competitiveness — without expanding its facility or increasing workforce numbers.
Reliable Long-Term Durability and Stable Performance
Long-term return on investment depends primarily on the quality of the blasting technology. The machine construction and blast wheel turbines supplied by our partner Gostol TST ensure high blasting efficiency and stable long-term performance. Increased turbine efficiency also results in improved energy and blasting medium utilisation while maintaining consistent surface quality. Wear parts are manufactured from highly durable materials, reducing the frequency of replacements and maintenance requirements. The new installation therefore delivered not only a doubling of production capacity, but also a stable and reliable foundation for the company’s continued manufacturing development.
