The large variety of workpieces and materials was one of the key points in the specification for the investment in new mass finishing technology at the Eingliederungsstätte Baselland ESB. In addition, the processing should become easier and more modern for the employees, as well as more environmentally friendly overall. Rösler implemented these requirements with a highly automated mass finishing solution. It consists of two rotary vibrators with automatic separation and parts transport to the new energy-saving dryer as well as a semi-automatic centrifuge for the resource-saving recirculation of the process water.
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The new automated mass finishing solution consists of two R 220 Euro rotary vibrators with automatic separation, which are connected to the RT 150 Euro DH dryer by a conveyor belt. A semi-automatic centrifuge Z 800 K-HA-TF is integrated to recirculate the process water |
Founded in 1975 and headquartered in Liestal, Switzerland, Eingliederungsstätte Baselland ESB is a private foundation operating under public mandate. The activities of the social enterprise aim to empower people in need of support to lead a self-determined life. To this end, around 100 residential facilities and 480 training and workplaces are available at 19 locations in the areas of assembly and packaging, mechanics, metal construction, electronics manufacturing and facility maintenance with professional support, guidance and advice.
Mechanical processing and mass finishing as a service
This includes the company in Liestal, where various processing steps such as turning, milling, drilling, thread cutting, grinding, sawing and reaming are offered as a service. The modern machinery enables the processing of steel, aluminum, non-ferrous metals and stainless steel as well as plastics. For both internally manufactured parts and externally produced workpieces, the service portfolio also includes deburring and edge rounding through mass finishing.
Easier, more comfortable and more environmentally friendly mass finishing
“Our systems were outdated and no longer met today's demands in terms of working comfort, ergonomics and sustainability. For example, the parts had to be manually removed from the work containers. In addition, the processes were carried out with fresh water, resulting in a high consumption of water and resources”, reports Sascha Berger, Co-Director at ESB in Liestal. In addition to the ability to easily process the enormously wide range of components, geometries and materials, the automation of the process and as simple control and handling as possible were key points in the specifications for the investment in new mass finishing systems. “It was essential for us to relieve our employees and encourage them to learn new things”, explains Sascha Berger. Another important requirement was the recirculation of the process water. In addition, the installation situation had to be considered, as the mass finishing processes are carried out in a room in the basement with a door that is only 1.20 m wide. With these requirements in mind, Sascha Berger reached out five manufacturers of mass finishing technology, including the Swiss location of Rösler Oberflächentechnik GmbH in Kirchleerau.
Mass finishing solution optimally tailored to requirements and wishes
After intensive discussions about the project, ESB chose the solution from Rösler Schweiz AG. It consists of two R 220 Euro rotary vibrators with automatic separation, whose screens can be exchanged easily and without tools and thus used for different parts. The vibrators are connected to the RT 150 Euro DH dryer by a conveyor belt. It has block heating elements that are directly coupled to the base plate of the processing bowl, enabling energy savings of up to 40 % compared to conventional dryers. A semi-automatic centrifuge Z 800 K-HA-TF is integrated into the solution to recirculate the process water, and its equipment has been designed to handle the variety of materials. “The key factor in our decision was that Rösler responded to our specifications in great detail and advised us extensively on our specific requirements. For example, the Rösler employee informed us exactly what we needed to consider when treating the process water contaminated with various metals”, explains Sascha Berger. Tests were carried out at the Customer Experience Center in Kirchleerau for the various components to be machined and used to define the respective machining parameters such as the use of suitable media, compound, processing intensity and time. The data determined in the process were stored as part-specific programs in the system control. “During the collaboration and the tests, Rösler provided us with a lot of mass finishing know-how. As a result, we now know what we are doing and what it takes to achieve our mass finishing goals in the best possible way”, adds Sascha Berger.
Fully automatic processing including parts separation and drying
In the first step, the employee selects the part-specific processing program on the control unit. The vibrators are each operated via a control panel with three buttons for starting, enabling separation and an unscheduled stop. By pressing the start button, the processing bowl begins to vibrate slightly in loading mode and is filled. After a set time, the vibrator switches to processing mode and the noise absorbing lid is closed by a two-hand control on the operating panel. At the end of the processing time, the system asks whether it is possible to separate directly. If this is the case, the separating flap is activated pneumatically. The media fall through the large separating screen back into the processing bowl and the parts are transported via the conveyor belt to the dryer, in which a natural product is used as a drying medium. It dries the parts in a single pass, and afterwards, they are automatically discharged into a container placed in front of the dryer. To reliably prevent parts from mixing, a new separation process for the rotary vibrator can only be released once the container has been removed. As long as the container has not been released, the processing bowl continues to vibrate at a reduced intensity. The workpieces remain in motion, which prevents corrosion, especially in the case of steel parts.
Over 50 % higher productivity and efficiency
Compared to the previous systems, the new mass finishing solution enables significantly shorter process times and at least 50 % higher throughput. At the same time, the consumption of fresh water and compound has been noticeably reduced by recirculating the process water. All of this contributes to making mass finishing more economical. “Basically, people are our top priority and our employees enjoy working with the new system much more. But of course, efficiency is also an aspect that we pay attention to, and we have also achieved a lot here”, concludes Sascha Berger.
