Rösler Retrofit and TuneUp service is a comprehensive upgrade program aimed at improving the performance, efficiency and longevity of existing shot blasting and mass finishing systems.
The process begins with a thorough inspection of the equipment and an evaluation of the production process. This assessment is followed by in-depth consultations with the client to identify enhancements tailored to their specific operational needs.
While the latest shot blasting and finishing technologies offer significant advancements, many of these innovations can be integrated into existing machinery. Retrofitting provides several advantages over purchasing new equipment. One of the most significant benefits is cost savings, as retrofitting often costs significantly less than acquiring new equipment. Another advantage is minimized disruption, as replacing large shot blasting installations can be costly and disruptive. Retrofitting allows companies to modernize their equipment without significant downtime. Many older machines still in operation can benefit from control system enhancements, such as replacing outdated PLCs and HMIs with modern alternatives that improve usability and reliability. Additionally, retrofitting contributes to environmental sustainability by extending the lifespan of existing equipment, reducing waste and lowering energy consumption.
One of the major benefits of retrofitting is cost efficiency. Many companies find that upgrading key components extends the lifespan of their machinery, making it a more financially viable solution. Enhanced performance is another advantage, as advanced blast wheels and modern control systems can boost equipment productivity. Rösler's Gamma blast wheels, for example, provide energy savings between 10% and 25% while increasing blasting performance by up to 77%, leading to reduced cycle times. Retrofitting also reduces downtime and maintenance costs. Obsolete components can be a major source of unexpected breakdowns, but modernizing control systems and upgrading core components enhance reliability. Furthermore, improved energy efficiency and sustainability lower operational costs.
Rösler's retrofit services cater to a wide range of industries, particularly those where high operator workloads, repetitive tasks and energy consumption are concerns. Automotive manufacturing benefits from automation and control system improvements that enhance precision and consistency. The aerospace industry requires advanced shot blasting for high-quality surface finishes on critical components. Foundries and heavy manufacturing operations, which use large-scale machinery that can be expensive to replace, find retrofitting a more practical choice.
Rösler's retrofit service begins with an initial consultation, followed by a site evaluation, where a Rösler expert assesses the equipment condition and determines the feasibility of retrofitting. Based on the evaluation, a customized proposal is presented, outlining potential upgrades, expected benefits and a return on investment analysis.
Once the proposal is approved, the necessary components are designed, manufactured and installed by Rösler's engineers. Finally, the upgraded system is fine-tuned for optimal performance during the commissioning phase, and operators receive training to ensure seamless integration.
Not all machines are ideal candidates for retrofitting. Several factors influence this decision, including the overall condition of the equipment. If a machine is in poor condition, a full replacement may be the better option. The availability of replacement components is another consideration, as some obsolete parts may be difficult to source, making retrofitting less viable. Finally, the potential for performance gains plays a crucial role. If significant enhancements can be achieved, retrofitting becomes an attractive and practical solution.
Retrofitting often involves several key technological upgrades. One of the most impactful improvements is blast wheel enhancement, where outdated blast wheels are replaced with high-performance models like the Gamma series, which improve energy efficiency and processing speeds. Control system modernization is another critical upgrade, with modern PLCs and HMIs enhancing usability and reducing the risks associated with obsolete components. The integration of automation into existing systems is increasingly popular, as it minimizes manual intervention, enhances efficiency and allows skilled labor to be used in other key functions.
A case study highlights the impact of retrofitting. A manufacturing client operating a shot blasting production cell required modernization to match the specifications of a new robotic automated system. Previously, the equipment required four operators per machine per week. After the retrofit, automation improvements reduced the need for manual operation to just one operator per shift, cutting production costs per part by 75-80%. The expected return on investment was projected within 12-18 months.
For more information contact:
Rosler Metal Finishing USA, LLC
1551 Denso Road
Battle Creek, MI 49037
269-441-3000
rosler-us@rosler.com