Tag Archives: Finishing

Science Research Technology

Gentle finishing of extremely thin work pieces with Turbotron centrifugal disk finishing machines

Deburring, edge radiusing, surface smoothing and polishing of mass-produced work pieces

Gentle finishing of extremely thin work pieces with Turbotron centrifugal disk finishing machines

Walther Trowal offers fully automatic systems with work piece loading and unloading

With the innovative option „gap rinsing“ the new Turbotron centrifugal disk finishing machines from Walther Trowal are ideal for finishing extremely thin fine-blanked parts. The new machines lower the investment expenditures and offer high uptimes.

Walther Trowal is the first supplier of mass finishing equipment who brings a new line of TT centrifugal disk finishing machines to the market with spinner and wear ring completely made from polyurethane and a rinsing system for the gap between spinner and stationary work bowl. This system prevents thin parts getting caught in the gap and get damaged. The new TT machines are a cost effective, highly wear resistant alternative to conventional mass finishing machines, especially for processing very thin work pieces.

To date the removal of burs and radiusing of edges on thin, relatively small parts required the use of centrifugal disk machines with special spinners made from ceramic or tungsten carbide steel. To prevent thin parts getting caught in the gap between the rotating spinner and stationary work bowl the precise setting of the gap was crucial for achieving the required finishing results.

Since even minor damage of the delicate spinner could result in high repair costs, the engineers at Walther Trowal were looking for a more economic solution.

The recently developed gap rinsing system now allows utilizing the spinners and wear rings Walther Trowal has been employing in large quantities in its standard centrifugal disk machines. This helps to drastically reduce the equipment expenditures, because PU is much less complicated to handle than, for example, ceramic materials. In addition, the gap size can be easily adjusted with the proven standard gap setting system. The pressure created by the rinsing system ensures that thin parts can no longer be drawn into the gap between spinner and wear ring.

Contrary to other mass finishing systems for deburring and grinding of thin components the new disk machines are operating with high water level in the work bowl. This helps prevent the work pieces from sticking to each other or clinging to the wall of the work bowl.

Christoph Cruse, general sales manager at Walther Trowal, sees significant benefits for his customers: “ Our new machines represent an economic, low-wear solution. Ceramic materials used to date are relatively brittle and can easily chip! This can cause costly damage to spinner and wear ring. Since we have worked with polyurethane for many years, we are very familiar with this material. To come to the heart of the matter: We have developed a smart, cost effective solution that works great for our customers.“

Walther Trowal offers the option „gap rinsing“ across the complete range of Turbotron disk finishing machines, from simple stand-alone units with manual work piece loading and unloading to large, fully automatic systems with hydraulic loader, external vibratory screening machine and media return conveyor.

Background:

Surface finishing with Turbotron centrifugal disk finishing machines

The high processing intensity, typical for the Walther Trowal centrifugal disk finishing machines, is achieved by the highly intensive interaction between processing media and work pieces and the high pressure of the media on the work piece surface created by the centrifugal force of the rotating spinner.

The spinner rotates with a speed of between 60 and 250 U/min. The centrifugal force created by this movement pushes the mix of work pieces, media and process water up the inner wall of the stationary work bowl. Once it has lost its kinetic energy the work piece/media mix collapses back to the spinner, from where it is accelerated again.

Facts about Walther Trowal

Since 1931 Walther Trowal develops, manufactures and markets modular and custom engineered solutions in the field of surface finishing.

Initially only making vibratory finishing equipment, over the years Trowal has continuously broadened its product range and today offers a wide portfolio of equipment and services for improving all kinds of surfaces, e.g. mass finishing, part cleaning, shot blasting and drying of a wide spectrum of parts, last but not least, the coating of mass produced small parts.

Walther Trowal offers not only various types of equipment but complete surface treatment systems: By linking the various equipment modules and automating the complete process, we are able to precisely adapt our process technologies to the technical requirements of our customers. This also includes various types of peripheral equipment and process water cleaning and recycling systems. Of course, we also offer comprehensive pre- and after-sale service like sample processing in one of our demonstration labs and global repair and maintenance service.

Walther Trowal serves many customers in many industries around the world. For example, in the automotive and aerospace industry, medical engineering and wind power generation.

Firmenkontakt
Walther Trowal GmbH & Co.KG
Christoph Cruse
Rheinische Str. 35-37
42781 Haan/Germany
+49 2129.571-209
+49 2129.571-225
c.cruse@walther-trowal.de
http://www.walther-trowal.de

Pressekontakt
VIP Kommunikation
Regina Reinhardt
Dennewartstraße 25-27
52068 Aachen/Germany
+49.241.89468-24
+49.241.89468-44
reinhardt@vip-kommunikation.de
http://www.vip-kommunikation.de

Science Research Technology

Walther Trowal: An amusement park ride served as idea for gentle finishing of high cost work pieces

New drag finishing machine works with overlapping rotational movements.

Walther Trowal: An amusement park ride served as idea for gentle finishing of high cost work pieces

The “Octopus” ride we all know from amusement parks provided the idea for the new machines.

Trowal developed the new drag finisher line M-TMD for processing work pieces requiring perfect surface finishes. The work pieces, mounted to rotating satellite stations, undergo multiple overlapping, pre-programmed, rotational movements. This rotational variation produces optimum finishing results.

Walther Trowal developed the new drag finisher specifically for finishing high value components, which must be handled with extreme care.

Typical work piece examples from the medical engineering industry are hip and knee implants requiring a high gloss polish. In the aerospace industry turbine blades and other components must receive a first-class finish with precise edge radiusing and very smooth surfaces. Examples from the automotive industry include the vanes of turbo chargers, which must not be nicked or damaged during the finishing process.

Christoph Cruse, General Sales Manager at Walther Trowal, foresees a big demand at those customers, who produce high precision, high value components: „With our new equipment line we address precision component manufacturers, who want perfect surface finishes, and where any blemishes like scratches could require scrapping a part. We also target manufacturers demanding tolerances of just a few microns. For these work pieces the M-TMD drag finishers with their optimum flow characteristics open entirely new possibilities.“

The functional principle: A rotation within the rotation

In standard drag finishers the work pieces are mounted to rotating work stations and „dragged“ through the grinding or polishing media. This movement creates a high processing intensity and produces excellent results on many parts.

In the new machines the work stations consist of multi spindle heads with each spindle holding one work piece. In addition to the carousel and work station rotation each spindle has its own rotational movement. In other words: The spindles move in a circle within two larger circles formed by the carousel and work station rotation. This is similar to the movement of the cabins in „Octopus“ rides that can be found at any amusement park.

The drag finisher M-TMD 4 is equipped with 4 multi spindle heads (work stations) with each head containing 3 spindles. In the M-TMD 6 up to 18 work pieces can be processed at the same time.

The independently adjustable rotational speed and rotational direction of the spindle heads and spindles creates a wide range of different movement patterns. In addition, the spindle heads can be tilted in different angles. This allows adjusting the flow characteristics to the specific shape of the various work pieces. With the PLC controller multi stage processing programs can be easily implemented.

During the finishing process the work bowl is vibrating for the optimum mixing of the grinding or polishing media. This guarantees a high degree of process consistency.
The media fines and undersize media, along with the metal fines from the work pieces, are continuously discharged from the machine; another contribution towards process stability and consistency.

Form surface grinding to high gloss polishing

The new Trowal machines can be operated in wet as well as dry processing mode. For surface grinding and smoothing, as well as for certain polishing operations, compound and water are used. In the case of targeted edge radiusing with tolerances of a few micron, for example, hard metal drill bits and milling heads, a dry process with special grinding granulate is utilized. Dry processing with organic polishing media and paste is also suitable for high gloss polishing.

Multiple finishing steps, from pre-grinding all the way to the final polishing stage, can take place in one single machine without the need to remove and remount the work pieces to the work stations: One work bowl filled with a certain finishing media can be easily and quickly removed with a pallet truck and replaced with a bowl containing another media.

Processing trials guarantee proven results

The first unit of the new machine generation has been installed in the Walther Trowal test lab in Haan/Germany. It is available for processing trials with customer work pieces allowing the customers to prove their finishing process, before making an investment decision. This ensures that the customer specifications can be fully met. Once the trials have yielded a viable process, the work piece range and quantity is analyzed to determine machine type & size, media & compound type, process water treatment system and drying method.

Background:
Drag Finishing
The drag finishing technology, developed by Walther Trowal about 30 years ago, has been continuously refined and, today, is an established finishing method that is ten to twenty times more efficient than conventional mass finishing systems.
The work pieces are individually mounted to rotating work stations integrated into a rotating carousel. During the process the parts never touch each other. Once the parts are mounted, the carousel with the work stations is lowered into a work bowl filled with grinding or polishing media. The work stations with the mounted work pieces are then „dragged“ through the stationary media mass. This translates into a highly efficient use of the kinetic energy between work pieces and media.
The new machines of the M-TMD series enlarge this effect by the addition of a third rotational movement of the spindles.

Facts about Walther Trowal

Since 1931 Walther Trowal develops, manufactures and markets modular and custom engineered solutions in the field of surface finishing.

Initially only making vibratory finishing equipment, over the years Trowal has continuously broadened its product range and today offers a wide portfolio of equipment and services for improving all kinds of surfaces, e.g. mass finishing, part cleaning, shot blasting and drying of a wide spectrum of parts, last but not least, the coating of mass produced small parts.

Walther Trowal offers not only various types of equipment but complete surface treatment systems: By linking the various equipment modules and automating the complete process, we are able to precisely adapt our process technologies to the technical requirements of our customers. This also includes various types of peripheral equipment and process water cleaning and recycling systems. Of course, we also offer comprehensive pre- and after-sale service like sample processing in one of our demonstration labs and global repair and maintenance service.

Walther Trowal serves many customers in many industries around the world. For example, in the automotive and aerospace industry, medical engineering and wind power generation.

Firmenkontakt
Walther Trowal GmbH & Co.KG
Georg Harnau
Rheinische Str. 35-37
42781 Haan/Germany
+49 2129.571-209
+49 2129.571-225
g.harnau@walther-trowal.de
http://www.walther-trowal.de

Pressekontakt
VIP Kommunikation
Regina Reinhardt
Dennewartstraße 25-27
52068 Aachen/Germany
+49.241.89468-24
+49.241.89468-44
reinhardt@vip-kommunikation.de
http://www.vip-kommunikation.de

Science Research Technology

The new generation of Trowal continuous shot blast machines is in operation

A Mexican manufacturer of automotive aluminum die-cast components now operates five continuous shot blast systems from Walther Trowal.

The new generation of Trowal continuous shot blast machines is in operation

The new THM troughed belt continuous shot blast machine equipped with turbines with curved throwing.

Walther Trowal has recently commissioned a THM troughed belt continuous shot blast machine for a customer in Mexico that is equipped with a brand new generation of blast turbines. These turbines were specifically designed for shot blasting of aluminum components. With a considerably higher blast media throwing speed the new turbines produce significantly shorter cycle times than the predecessor models.

The Mexican customer already operates very successfully four continuous Trowal shot blast machines. Because of their excellent performance he chose to purchase another THM machine, when he had to expand his production capacity.

Up-and-coming: Aluminum, the gentle blast media

The increasing sales trend at Walther Trowal indicates that ever more customers are switching to aluminum media when shot blasting aluminum components. Because of its lower bulk density aluminum media is a lot gentler than, for example, stainless steel shot. Typical automotive forgings made from aluminum are, for example, steering knuckles or swivel bearings. Aluminum die-castings processed in THM shot blast machines can be all kinds of housings, covers or levers.

Because of its lower density the impact energy of aluminum media on the work pieces is considerably lower compared to other blast media. To offset this limitation Walther Trowal developed turbines with curved throwing blades, which generate a significantly higher blast media throwing speed than straight blades. This, combined with the fact that in THM machines the turbines are located very close to the work pieces, and the media throughput is considerably higher, results in optimized energy utilization and surprisingly short cycle times. However, the shot blast treatment remains very gentle. In short, despite the relatively low density of aluminum blast media, the shot blast process is highly effective and at the same time surprisingly gentle preventing any warping or distortions of delicate work pieces.

Another benefit of aluminum blast media is that it reduces the wear rate in the turbines and the machine to a fraction of the wear caused by steel shot, resulting in higher uptimes and lower operating costs.

Walther Trowal offers a range of different machine sizes equipped with up to four turbines. For example, for forged aluminum components the new THM 700/4/E with 4 turbines and a power of 15 kW for each turbine, produces an exceptionally high degree of productivity.

Specifically designed for handling aluminum media

To meet all the challenges posed by aluminum shot the Trowal engineers redesigned many machine assemblies, among them the media dosing system and the turbines. One detail of many: A rough surface of the throwing blades would quickly destroy the aluminum particles. Therefore, Walther Trowal is smoothing the blade surface with in-house vibratory finishing equipment. The result: A greatly reduced blast media consumption, lower dust emissions and significantly improved turbine uptimes.

Gentle work piece transport

THM troughed belt continuous shot blast machines are equally well suited for treating mass-produced bulk parts or large, delicate components. Especially with delicate, somewhat fragile work pieces the THM concept offers significant advantages: In these systems the work pieces are evenly distributed through the entire machine length. This results in a very gentle transport and prevents intensive part-on-part collisions. And the fact that the transport rods are covered with a relatively soft PU further cushions the already gentle tumbling action. This is particularly important for fragile components with thin walls, allowing them to be discharged from the machine without any nicking or other damage.

No problem with older THM systems!

When developing the new turbines Walther Trowal also took into consideration the many older machines still in operation: Any THM customer who wants to take advantage of the new turbines can easily install them in his existing machine(s). This allows the customers to increase the efficiency of their shot blast operation with minimal costs.
For THM systems still requiring steel or stainless steel blast media, Walther Trowal supplies the new turbines with the curved throwing blades made from tool steel also offering significantly higher turbine uptimes.

Facts about Walther Trowal

For 85 years Walther Trowal has been a pioneer and market leader in various surface treatment technologies. The company offers modular and custom engineered solutions for a wide range of surface treatment problems.

Initially only making vibratory finishing equipment, over the years Walther Trowal has continuously broadened its product range and today offers a wide portfolio of equipment and services for improving all kinds of surfaces, e.g. mass finishing, part cleaning, shot blasting and drying of a wide spectrum of work pieces, last but not least, the coating of mass produced small parts.

Walther Trowal offers not only various types of equipment but complete surface treatment systems: By linking the various equipment modules and automating the complete process, we are able to precisely adapt our process technologies to the technical requirements of our customers. This also includes various types of peripheral equipment and process water cleaning and recycling systems. Of course, we also offer comprehensive pre- and after-sale service like sample processing in one of our demonstration labs and global repair and maintenance service.

Walther Trowal serves many customers in many industries around the world. For example, in the automotive and aerospace industry, medical engineering and wind power generation.

Firmenkontakt
Walther Trowal GmbH & Co.KG
Georg Harnau
Rheinische Str. 35-37
42781 Haan/Germany
+49 2129.571-209
+49 2129.571-225
g.harnau@walther-trowal.de
http://www.walther-trowal.de

Pressekontakt
VIP Kommunikation
Regina Reinhardt
Dennewartstraße 25-27
52068 Aachen/Germany
+49.241.89468-24
+49.241.89468-44
reinhardt@vip-kommunikation.de
http://www.vip-kommunikation.de

English Press Releases

Heinrich Georg Maschinenfabrik delivers the fourth Roll Lathe to Trinec

Rough and Finish Machining of Profile Rolls in the Steel Industry

Heinrich Georg Maschinenfabrik delivers the fourth Roll Lathe to Trinec

Already in use in Trinec: A GEORG Roll Lathe Type ultraturn 1500 R for profile rolls.

Last December, Heinrich Georg GmbH Maschinenfabrik received an order for the delivery of a roll lathe for up to 10 t of workpiece weight from Czech company Strojirny a Stavby Trinec, a.s. This is already the fourth machine ordered in Kreuztal by the subsidiary of Trinecke zelezárny a.s. since 1996.

The new Roll Lathe Type GEORG ultraturn 900 R will be used for new machining and finishing of profile rolls, by means of which Trinecke zelezárny mainly produces round profiles, flat sections, angle profiles as well as reinforcing steel for the construction industry.

The machine is designed for rolls with a diameter of up to 900 mm and a weight of up to 10 t and a center width of 2.500 mm. The tool holder in slide design with one tool slide ensures a safe transmission of highest cutting forces.

Already in 1996 and 2003 GEORG delivered two machines for workpiece weights of up to 40 t, in 2004 another machine for rolls up to 10 t. The new machine completes the roll workshop equipment, having four GEORG machines in operation in the future. The production capacity expansion makes this investment necessary. All four machines are fully hydrostatic guided, a concept which GEORG generally applies for all its roll lathes. The biggest machines of the ultraturn range can handle workpieces with weights of up to 300 t and more. The machine enables heavy roughing with high cutting parameters as well as finishing with highest demands on accuracies. In this way, the customer additionally saves time for workpieces setup.

In contrast to more simple linear-guided or slide guided machines there are almost no running costs for loss lubrication or guiding elements exchange as it is the case for hydrostatic guided machines. Furthermore, based on the design principle, these machines achieve the same accuracy as new machines, even after heavy use in a roll shop for decades. By receiving this order, Jan Ebener, Head of Sales for GEORG´s Machine Tool Division, believes the concept of hydrostatic guided machines to be proven:

„Besides the quality of our machines, our customers obviously also appreciate their efficiency. Thus, we have succeeded against strong domestic and foreign competitors. Lathes equipped with the hydrostatic and wear-free guideways are more expensive to purchase, but more efficient and economically over the years and decades.“

GEORG will deliver the machine in autumn 2016.

Background:

GEORG- Roll Lathes cost advantages

The extremely robust construction of the GEORG Roll Lathes reflects its advantages after only a few years of operation time: In comparison to lighter or not fully hydrostatic machines, they generate much lower costs for the operating time duration. The lifecycle costs are reduced by high maintainability and low operating costs as well as by using wearfree hydrostatic guideways or high availability of stable and proven components. Due to wide machine beds and overall more stable machine, the maintenance intervals are extended and thus lead to much lower operating costs. Shorter machining times increase the productivity and hence reduce the unit prices.

www.georg.com

Firmenkontakt
Heinrich Georg GmbH Maschinenfabrik
Machine Tool Division
Langenauer Straße 12
57223 Kreuztal / Germany
+49. 2732 779-306
+49. 2732 779-316
wzm@georg.com
www.georg.com

Pressekontakt
VIP-Kommunikation
Regina Reinhardt
Dennewartstraße 25-27
52068 Aachen / Germany
+49.241.89468-24
+49.241.89468-44
reinhardt@vip-kommunikation.de
www.vip-kommunikation.de

Science Research Technology

Walther Trowal: New rotary drum coater for work pieces that are heavy or have complex geometries

Walther Trowal: New rotary drum coater for work pieces that are heavy or have complex geometries

At the Paint Expo Walther Trowal presents the new R 80 Rotamat drum coater.

At the Paint Expo Walther Trowal presents the new R80 Rotamat for coating of mass-produced small parts made from plastic, metal, rubber and wood.

With a drum diameter of 800 mm and a usable volume of 50 l the new machine can accommodate batches of 50 kg. This is of particular interest to customers, who must coat parts with complex geometries or heavy parts, which, for example are made from metal.

With technical features like optimized fresh air inlet and a modular filter system – up to filter class F6 – this machine offers a high degree of flexibility regarding the use of different paints with, at the same time, a higher throughput. By being able to use more solvent the users can speed up the coating process and still remain within the ATEX limits.

First reports from the field indicate that the new coater so far has not only fully met but exceeded expectations.

By optimizing the airflow and the paint spraying system, Walther Trowal was able to keep overspray at an absolute minimum. And finally, the new heat control system helps reduce cycle times and energy consumption.

Walther Trowal at Paint Expo 2016
(April 19 – 21, Karlsruhe/Germany):
Hall 2, Booth 2310

Facts about Walther Trowal

For more than 80 years Walther Trowal has been a pioneer and market leader in various surface treatment technologies. The company offers modular and custom engineered solutions for a wide range of surface treatment problems.

Initially only making vibratory finishing equipment, over the years Walther Trowal has continuously broadened its product range and today offers a wide portfolio of equipment and services for improving all kinds of surfaces, e.g. mass finishing, part cleaning, shot blasting and drying of a wide spectrum of work pieces, last but not least, the coating of mass produced small parts.

Walther Trowal offers not only various types of equipment but complete surface treatment systems: By linking the various equipment modules and automating the complete process, we are able to precisely adapt our process technologies to the technical requirements of our customers. This also includes various types of peripheral equipment and process water cleaning and recycling systems. Of course, we also offer comprehensive pre- and after-sale service like sample processing in one of our demonstration labs and global repair and maintenance service.

Walther Trowal serves many customers in many industries around the world. For example, in the automotive and aerospace industry, medical engineering and wind power generation.

Firmenkontakt
Walther Trowal GmbH & Co.KG
Frank Siegel
Rheinische Str. 35-37
42781 Haan/Germany
+49 2129.571-209
+49 2129.571-225
f.siegel@walther-trowal.de
http://www.walther-trowal.de

Pressekontakt
VIP Kommunikation
Regina Reinhardt
Dennewartstraße 25-27
52068 Aachen/Germany
+49.241.89468-24
+49.241.89468-44
reinhardt@vip-kommunikation.de
www.vip-kommunikation.de

English Press Releases

Improved grinding performance, excellent surface finishes and less media wear

A new high-density media combines the advantages of plastic and ceramic media in one product

Improved grinding performance, excellent surface finishes and less media wear

Finishing of die-castings in a CB 400 rotary vibrator from Walther Trowal.

With the newly developed fast cutting plastic media „trowalplast HDC“ Walther Trowal offers a product that is ideal for grinding and surface smoothing of metal work pieces, especially die-castings. The high density and sharp edges of the embedded abrasive material contribute to a drastic shortening of process times. But they also produce excellent surface finishes at a surprisingly low wear rate.

Walther Trowal has pioneered the development of the new HDC media (High Density Cut) and is now introducing it in the German market. This media consists of a plastic carrier filled with zirconium silicate, thus combining the advantages of lightweight plastic media with the extremely high density of the abrasive filler material. This combination yields metal removal rates that are comparable to ceramic media with, at the same time, a surprisingly low wear rate and excellent surface finishes.

Angelika Helten, head of the chemical lab at Walther Trowal, comments on the reasons for developing this new media type: „Many of our customers would love to work with ceramic media, because their finishing tasks require a high grinding performance. But ceramic media tends to chip and frequently wears relatively fast. That is why they are using plastic media, which produces the required finishing results, but at much longer processing times. Our new HDC media combines the advantages of plastic and ceramic and is, therefore, the ideal solution.“

An excellent application for the new HDC product is the finishing of die-castings, for which until now plastic media – for example the type „ET“ from Walther Trowal – has been used.

The HDC is equally effective in all types of mass finishing equipment. This applies to high-energy centrifugal disk finishing machines, which generally cause a very high wear rate of ceramic media, as well as to linear continuous feed vibratory systems, which only allow a relatively narrow band of processing times. Especially in these machines the HDC is particularly effective, because it produces significantly better finishing results at the prescribed cycle times.

Christoph Cruse, general sales manager at Walther Trowal, wants to make it easy and simple for the customers to test the new high density media: „Those customers who are already using our equipment can simply order a machine load of the new media and test it in their machine. For new customers, who consider investing in a mass finishing machine, we offer processing trials in our test lab free of charge.“

Improved grinding performance

Because of its relatively high bulk density and the sharp edges of the abrasive material the HDC offers grinding characteristics similar to ceramic media.

Besides the actual material content the media shape plays a significant role. While ceramic media are only available in relatively few shapes, the HDC can be produced in all the known shapes and sizes for plastic media. This allows Walther Trowal to offer media that are perfectly adapted to the different work piece shapes and sizes. Initially, the company will offer the HDC as 8 mm (0.3″) cones. This is the smallest size available on the market. And it is ideal for finishing work pieces with many internal corners and passages.

For the daily mass finishing operations the media color is also an advantage: Contrary to the mostly grey ceramic media the HDC with its pink color can be easily recognized in case of media lodging in the work pieces.

Lower wear rate

To date a high grinding performance automatically meant a high wear rate. With the HDC media this is different: Despite its high metal removal rate, in comparison to other fast cutting media in the Walther Trowal product range the high-density media is wearing relatively slowly.

No silica and alumina

The HDC media is filled with zirconium silicate. Besides the fact that the abrasive grains have exceptionally sharp edges, this abrasive has the added advantage that it does not contain any aluminum oxide or silicon dioxide. Therefore, it can be used for work pieces, which must not be in contact with these two materials. With the HDC Walther Trowal can now offer a range of fine grinding and fast cutting media that does not contain aluminum oxide.

Facts about Walther Trowal

For more than 80 years Walther Trowal has been a pioneer and market leader in various surface treatment technologies. The company offers modular and custom engineered solutions for a wide range of surface treatment problems.

Initially only making vibratory finishing equipment, over the years Walther Trowal has continuously broadened its product range and today offers a wide portfolio of equipment and services for improving all kinds of surfaces, e.g. mass finishing, part cleaning, shot blasting and drying of a wide spectrum of work pieces, last but not least, the coating of mass produced small parts.

Walther Trowal offers not only various types of equipment but complete surface treatment systems: By linking the various equipment modules and automating the complete process, we are able to precisely adapt our process technologies to the technical requirements of our customers. This also includes various types of peripheral equipment and process water cleaning and recycling systems. Of course, we also offer comprehensive pre- and after-sale service like sample processing in one of our demonstration labs and global repair and maintenance service.

Walther Trowal serves many customers in many industries around the world. For example, in the automotive and aerospace industry, medical engineering and wind power generation.

Firmenkontakt
Walther Trowal GmbH & Co.KG
Klaus Peter Neidhardt
Rheinische Str. 35-37
42781 Haan/Germany
+49 2129.571-209
+49 2129.571-225
kp.neidhardt@walther-trowal.de
http://www.walther-trowal.de

Pressekontakt
VIP Kommunikation
Regina Reinhardt
Dennewartstraße 25-27
52068 Aachen/Germany
+49.241.89468-24
+49.241.89468-44
reinhardt@vip-kommunikation.de
www.vip-kommunikation.de

Science Research Technology

Walther Trowal offers more reliable finishing results

Walther Trowal offers more reliable finishing results

After being “trowalized” a grease retaining disk is perfectly cleaned.

No matter what water hardness you must work with, the newly developed broadband compounds are considerably less foaming.

Walther Trowal is the only supplier in the industry offering compounds for the surface finishing of metal parts which work entirely independent from the hardness of the process water and produce practically no foam. This is great news for the users, because their „trowalizing“ processes run now absolutely stable irrespective of the ambient operating conditions. Since they contain synthetically manufactured raw materials instead of soap, the new compounds also contribute to a cleaner environment.

With soap-based compounds the optimum balance between a good cleaning effect and acceptable foaming has been limited to a very narrow water hardness range. Even minor fluctuations of the water hardness could jeopardize the stability of the entire finishing process.

The solution – Special surfactants

With the new broadband compounds trowal KRA, trowal SGK and trowal KRS Walther Trowal was able to completely eliminate the negative effects of the water hardness. This guarantees absolutely stable finishing processes over a wide range of process water hardness.

The new compounds contain special surfactants instead of different types of soaps. The result: Very little foaming under practically any operating condition and extremely simple handling. Auxiliary compounds like de-foamers, hardness-augmenting agents or, for some applications, additional machinery are no longer required. „Foam parties“ are a thing of the past, at least in the field of mass finishing.

With their wide application range relative to the water hardness the new compounds offer a high degree of operational stability: The hardness of the process water is not a limiting factor anymore. This means that the user does no longer have to choose between different water supply companies, install an in-house water softener or deal with fluctuating water characteristics – his mass finishing processes remain unaffected by the water hardness!

Of course, this means also that the new compounds can be utilized at any location without the risk of jeopardizing the specified finishing results. This offers a big advantage for users with multiple manufacturing facilities. And at the same time it ensures that the results of processing trials run at the Walther Trowal demonstration lab in Haan during the pre-sale phase are absolutely repeatable at the customer premises.

The new Trowal compounds have excellent cleaning, degreasing and corrosion protection characteristics. They produce bright and shiny surfaces. In addition, they emulsify oil very efficiently resulting in excellent degreasing results. They also effectively disperse the metal and media fines generated by the finishing process, thus allowing the process water to easily flush them out of the processing bowl. Additional low foaming inhibitors provide excellent corrosion protection.

Customer feedback highly positive

Users who switched to the new compounds report that their mass finishing processes are running absolutely free of any trouble and that since the changeover no service support from Walther Trowal was required.

A manufacturer of needles for textile machinery was the first customer using the new Walther Trowal compounds. Although the process water used at this customer“s premises is very soft, the addition of hardness augmenting agents is no longer necessary. Another significant benefit of the new compounds is the fact that the process water can now be recycled over a very long period requiring only fresh water replenishment due to evaporation loss.

„Green compounds“ protect our environment and save valuable resources.

When developing the new broadband compounds Walther Trowal focused to a large extent on environmental protection: The basic ingredients are synthetically produced materials replacing palm oil which is the major substance for soap production and is also found in many food items. In recent years palm oil has become highly controversial because of environmentally hazardous growing and harvesting methods.

For many mass finishing applications the new compounds aIlow recycling of the process water for the very first time resulting in significant cost savings for fresh water and waste water disposal.

The new broadband compounds

trowal KRA: An all-round compound

trowal KRA is a universal cleaning and degreasing compound with excellent corrosion protection characteristics. It is suitable for all metals and is mostly used for deburring of work pieces that may contain some surface oil but do not require intensive degreasing.

trowal SGK: Excellent degreasing characteristics

Walther Trowal developed the trowal SGK compound specifically for degreasing and cleaning of parts made from aluminum, stainless steel and zinc. It has excellent degreasing characteristics and can also be used for the removal of stubborn surface contaminations.

trowal KRS: Vey good corrosion protection

trowal KRS is ideal for finishing of ferritic work pieces that tend to rust easily. It contains special surfactants that effectively disperse the metal and media fines and, thus, protect the surface of the parts against corrosion.

The detrimental relationship between soap and water
hardness

The reason for the negative impact of water hardness in conjunction with soap-based compounds is the fact that soap reacts completely different in operating conditions with varying degrees of water hardness. In soft water soap has excellent cleaning characteristics and emulsifies oil very well. However, when the process water is recycled, it produces a lot of foam necessitating the use of de-foamers. Furthermore, the soap does not adhere to the surface, i.e. it does not create a protective surface film insulating the surface from the environment. The result: Poor corrosion protection.

On the other hand, in hard water the corrosion protection of soap-based compounds is quite good, and very little foam is generated. But this comes at the price of diminished cleaning capabilities. In addition, the soap in connection with hard water hinders the emulsification of oil resulting in an insufficient degreasing effect.

Facts about Walther Trowal

For more than 80 years Walther Trowal has been a pioneer and market leader in various surface treatment technologies. The company offers modular and custom engineered solutions for a wide range of surface treatment problems.

Initially only making vibratory finishing equipment, over the years Walther Trowal has continuously broadened its product range and today offers a wide portfolio of equipment and services for improving all kinds of surfaces, e.g. mass finishing, part cleaning, shot blasting and drying of a wide spectrum of work pieces, last but not least, the coating of mass produced small parts.

Walther Trowal offers not only various types of equipment but complete surface treatment systems: By linking the various equipment modules and automating the complete process we are able to precisely adapt our process technologies to the technical requirements of our customers. This also includes various types of peripheral equipment and process water cleaning and recycling systems. Of course, we also offer comprehensive pre- and after-sale service like sample processing in one of our demonstration labs and global repair and maintenance service.

Walther Trowal serves customers all over the world in many industries, for example, automotive, aerospace, medical implants and wind energy.

Firmenkontakt
Walther Trowal GmbH & Co.KG
Georg Harnau
Rheinische Str. 35-37
42781 Haan/Germany
+49 2129.571-209
+49 2129.571-225
c.cruse@walther-trowal.de
http://www.walther-trowal.de

Pressekontakt
VIP-Kommunikation
Regina Reinhardt
Süsterfeldstrasse 83
52072 Aachen/Germany
+49.241.89468-24
reinhardt@vip-kommunikation.de
http://www.vip-kommunikation.de

English Press Releases

Commissioning of complete finishing line for up to 100-m-long rails

Commissioning of complete finishing line for up to 100-m-long rails

The cooling bed can handle rails of more than 100 m length.

Rolling mill Technology: Successful completion of final acceptance tests of the new line in West Siberia

Last September, EVRAZ ZSMK commissioned and issued the FAC for the new rail finishing line at its works in Novokuznetsk, West Siberia.

The new rail finishing line installed in the Novokuznetsk works of the metallurgical combine EVRAZ ZSMK has been successfully commissioned. The line designed for handling rails more than 100 m long was designed and supplied by Koch H&K Industrieanlagen GmbH.

The order comprised all components from the rolling mill exit through to the loading area for the straightened and finished rails. Koch H&K supplied the cooling bed, a buffer bed and a PS 1800 H-type pendulum shear used for sample taking, several sawing machines for cutting the rails to length, the drilling equipment and the complete plant control systems.

Koch H&K also provided the entire transport and handling equipment including the charging and discharging devices and the roller tables. The manipulator for loading the finished rails into intermediate storage devices or directly onto rail wagons was also part of the order scope. The manipulator, which has a span width of 100 m, is designed to securely prevent any damage to the rails.

The weather conditions in the Siberian plant posed the designers with an extraordinary challenge. All equipment had to be designed for temperatures between -20 and +40 °C. For weeks, the equipment installation had to take place at deep freezing temperatures.

Koch H&K supplied the plant on a turnkey basis, including the hydraulics, the media supply equipment and all automation and control systems. The plant can process 100-m-long rails at a cycle time of 120 seconds.

Alone the transport of the plant components, which were up to 30 m long and had a total weight of some 2,600 t, was a highly challenging task. It required a total of 170 railway wagons and, what is more, at the Russian border the freight had to be reloaded onto wagons suitable for the Russian broad-gauge lines.

About Koch H&K

Koch H&K Industrieanlagen GmbH was established in 2010 by the company“s current Executive Partners who acquired the assets in a management buy-out of the business area „Rolling Mill Technology“ from the Danish company FLSmidth. The company has its roots in the two companies Koch Transporttechnik GmbH and Hoestemberghe & Klütsch GmbH, which were both founded more than 60 years ago. Through this background, Koch H&K can build on more than six decades of steel industry experience.

The company develops and provides integrated solutions for rolling mills, from continuous casting through to the finish-rolled section or sheet. It specializes in customized solutions for both new plants and plant modernizations, which are supplied complete with automation, control and network systems and all ancillary equipment.

The range of products comprises
– Rolling equipment: hot rolling stands for long products such as sections, special sections or steel bars
– Conveying equipment: roller tables, skids, loading beds, turnover and shifting devices,
– Machining and finishing equipment for cutting, sawing, shearing, cooling and straightening.

Koch H&K plans, designs, manufactures and supplies its plants on a turnkey basis, including installation and commissioning, operator training and service. The company currently has a workforce of 80. Many of them are engineers and technicians specialized in mechanical or electrical engineering, automation and civil engineering.

Kontakt
Koch H&K Industrieanlagen GmbH
Nicolas Fritzen
Kochstraße 2
66783 Dillingen/Saar (Germany)
+49.6831-89446-0
info@koch-hk.com
http://www.koch-hk.com

Pressekontakt:
VIP-Kommunikation
Regina Reinhardt
Süsterfeldstrasse 83
52072 Aachen / Germany
+49.241.89468-24
reinhardt@vip-kommunikation.de
http://www.vip-kommunikation.de

Wirtschaft Handel Maschinenbau

Pitney Bowes und Sitma Machinery entwickeln Mail-Finishing-Plattform der nächsten Generation

Heppenheim, 13. April 2011 – Pitney Bowes gibt eine weitreichende Kooperation mit Sitma Machinery S.p.A. bekannt. Ziel ist es, eine Mail-Finishing-Plattform der nächsten Generation zu entwickeln, mit der qualitativ hochwertige Kundenkommunikation zu einem niedrigeren Stückpreis erstellt werden kann.

Die Plattform kombiniert die Erfahrung von Pitney Bowes im Bereich Hochgeschwindigkeitskuvertierer, Software-Lösungen und Dienstleistungen mit der innovativen Verpackungslösung von Sitma Machinery. Diese neue Mail-Finishing-Plattform hilft den Kunden dabei, die Kosten für ihre Versand- und Druckaufgaben zu reduzieren, ohne Kompromisse bei der Integrität einzugehen.

„Jedes Jahr steigen die Erwartungen in den Produktionshallen, was Verbesserungen und höheren Return-on-Investment von Druck- und Versandlösungen betrifft“, sagt Grant Miller, Vice President Global Strategic Product Management and North American Sales, Document Messaging Technologies, Pitney Bowes. „Durch unsere Kooperation mit Sitma Machinery erhalten unsere Kunden Zugang zu einer fortschrittlichen Mail-Finishing-Plattform, die dabei hilft, die Effizienz zu steigern, Kosten zu senken und Druck- und Versandprozesse zu verknüpfen.“

„Wir freuen uns, mit Pitney Bowes zusammen eine integrierte Mail-Finishing-Lösung zu entwickeln, die Großversendern eine höhere Produktivität ermöglicht“, sagt Aris Ballestrazzi, President und Mitinhaber von Sitma Machinery. „Als wichtige Komponente dieser Plattform wird die Verpackungslösung von Sitma Machinery dazu beitragen, die Arbeitsplatzeffizienz und die Flexibilität bei Aufträgen zu steigern.“

Kunden aus aller Welt können diese innovative Mail-Finishing-Plattform auf dem jährlichen „Customer Summit“ von Pitney Bowes vorab sehen, der vom 6.-8. Juni 2011 vom Geschäftsbereich Document Messaging Technologies in Danbury, Connecticut, veranstaltet wird.

Die neue Mail-Finishing-Plattform wird zukünftig ein wichtiges Element sein, um wirksame, relevante Kundenkommunikation zu erstellen. Pitney Bowes bietet eine einzigartige End-to-End-Lösung, die hilft, Druck- und Versandprozesse zu einer White-Paper-Factory-Lösung umzustellen. Das IntelliJet-Drucksystem, die Output-Management-Software Production Intelligence und die Hochgeschwindigkeits-Finishing-Systeme mit dem Print+-Messenger-Modul für farbigen Kuvert-Inkjetdruck ermöglichen höhere Produktivität und geringere Betriebskosten. Alle diese Systeme werden für höchste Effizienz und Leistung durch ein Service-Team unterstützt. Gemeinsam bilden diese Elemente eine integrierte Lösung für Unternehmen, in denen Post eine strategische Rolle in der Kundenkommunikation spielt.

Über Pitney Bowes

Seit mehr als 90 Jahren bietet Pitney Bowes innovative Lösungen, um physische und digitale Kommunikationskanäle effizient und gewinnbringend miteinander zu verbinden. Das Portfolio des Weltmarktführers im Bereich Post- und Dokumentenmanagement umfasst Software, Hardware und verschiedene Dienstleistungen, mit denen Kunden ihre Produktivität steigern können. Zunehmend unterstützt Pitney Bowes Unternehmen auch bei der Erschließung neuer Geschäftsfelder – mit fortschrittlichen Lösungen im Bereich Customer Communications Management (CCM). Pitney Bowes erwirtschaftet einen Jahresumsatz von rund 5,4 Milliarden US-Dollar und beschäftigt weltweit 30.000 Mitarbeiter.

Seit 1961 ist die Pitney Bowes Deutschland GmbH auf dem deutschen Markt tätig und hat seither auch hier ihre Marktposition ständig ausbauen können. Die Deutschlandzentrale von Pitney Bowes hat ihren Sitz in Heppenheim (Hessen). Niederlassungen in Hamburg, Berlin, Hannover, Leipzig, Dresden, Bielefeld, Neuss, Köln, Stuttgart und München sorgen für ein flächendeckendes Vertriebs- und Servicenetz. Aus Heppenheim werden auch die Aktivitäten in Österreich und in der Schweiz gesteuert.

Pitney Bowes: Every connection is a new opportunityTM.

Pitney Bowes Deutschland GmbH (Bereich DMT)
Annette Friedl
Tiergartenstr. 7
64646 Heppenheim
06252 708 325

annette.friedl@pb.com

Pressekontakt:
Maisberger GmbH
Martina Eder
Kirchenstraße 15
81675 München
martina.eder@maisberger.com
089 41 95 99 26
http://www.maisberger.com