Rösler’s RMBS 1-6-400-30 has revolutionised engine block cleaning at Turkey’s largest foundry – thus boosting efficiency, reducing labour and freeing up space.
Rösler has introduced a groundbreaking solution for Turkey’s largest foundry, revolutionising its de-sanding and cleaning process with the RMBS 1-6-400-30 shot blast system. This state-of-the-art machine was selected for its advanced automation in workpiece handling and blasting, drastically reducing cycle times compared to traditional spinner hanger machines. Its efficiency has also allowed the foundry to replace two older blast machines, creating additional manufacturing space and optimising operations.
Renowned for producing grey and nodular cast iron engine blocks for commercial vehicles and ships, the foundry had previously relied on two separate spinner hanger machines—one for de-sanding and another for general cleaning. However, rising production volumes turned shot blasting into a bottleneck, necessitating a more efficient alternative. After evaluating solutions from four manufacturers, the foundry chose Rösler Oberflächentechnik GmbH for its innovative and tailored design that meets the specific requirements of engine block cleaning.
Shot blast machine tailored to engine blocks
Rösler’s RMBS 1-6-400-30 machine is specifically designed for engine block cleaning. It allows fully automated, simultaneous cleaning of either one large engine block or several smaller ones within short cycle times. The system features a custom-engineered gripper-manipulator. A robot places the engine block into the blast chamber, where the gripper secures and rotates it precisely through the blast media stream. The rotation speed can be adjusted or paused to ensure thorough exposure of specific surfaces. For smaller engine blocks, multiple pieces can be mounted onto a specialised fixture, which is then handled in the same manner.
Enhanced efficiency and reduced labour costs
With the old spinner hanger system, workpieces had to be manually loaded onto hangers for blasting. The new Rösler system eliminates this step by automating the process and combining de-sanding and surface cleaning into a single operation. This improvement has dramatically increased throughput, making the two older machines redundant. The design also eliminates the risk of workpiece areas being shielded from the blast stream, ensuring consistent results. Furthermore, the reduced need for manual intervention lowers labour costs, a critical advantage in an industry where physically demanding roles are increasingly difficult to fill.
Durable design minimises maintenance and operating costs
The RMBS system uses six Gamma 400G-8 HD blast turbines, each with a drive power of 30 kW. These turbines, specifically developed for foundry applications, feature eight “Y-design” throwing blades for up to 20% higher blast intensity while consuming less energy. The blades’ unique design doubles their usable lifespan by allowing both sides to be used. Maintenance is simplified with a quick-change system that eliminates the need to remove the turbine from its housing. The blast chamber itself is built for durability, constructed from sturdy manganese steel and lined with wear-resistant plates that are easy to replace. Areas directly exposed to the blast stream are reinforced with special cast wear plates, ensuring long-term reliability.
So, by adopting Rösler’s RMBS 1-6-400-30 shot blast machine, the Turkish foundry has achieved faster, more efficient cleaning of engine blocks with reduced labour and maintenance costs. This innovative system not only addresses the challenges of rising production demands but also sets a new benchmark for operational efficiency in the foundry industry.