Gentle finishing of extremely hard surfaces

Overlapping rotational work piece movement is the basis for even, all-around surface finishes

Gentle finishing of extremely hard surfaces

The spindles allow the processing of batches of up to 18 work pieces. For this photo different work

At this year“s IMTS Walther Trowal is introducing the new drag finisher M-TMD 6M for treating high-value components that require a first-class surface quality. The new drag machines will place a mirror polish on the hardest materials – even on ceramic components. With these machines the costs for polishing can be reduced to a fraction of the costs for manual surface grinding and polishing. But even more important: They ensure absolutely repeatable, high-quality finishing results within an extremely narrow tolerance band.

Walther Trowal developed these new machines specifically for treating high-value components requiring extremely careful handling for the complete finishing process. For example, they are utilized for finishing the surface of turbine blades, impellers for turbo chargers, precision components for pumps and compressors as well as for orthopedic implants.

The new drag machines of the M-series have a carousel with multiple rotating workstations. In turn each workstation is equipped with spindle heads containing several spindle drives onto which the work pieces are attached with special fixtures. In addition, these machines also contain a stationary work bowl filled with grinding or polishing media. As the work pieces are „dragged“ through the stationary media mass, the simultaneous rotational work piece movement by carousel, workstations and spindles creates different overlapping patterns, which ensure an even and intensive coverage of the complete work piece surface.

Christoph Cruse, director of sales at Walther Trowal, foresees a big demand for these machines at some of his customers who produce delicate, high-value components. He explains: „With our new machines we want to assist the manufacturers of work pieces that must receive the best possible surface finish, and where even the slightest surface flaw or scratch might cause them to be scrapped. Furthermore, we target parts where deviations from the dimensional specifications of a few thousands mm can be a detrimental. The M-TMD drag finishers with their perfect surface coverage open brand-new possibilities for finishing such work pieces.“

Die M-TMD 4 drag finisher is equipped with four work stations and can process 12 parts in one single batch; the M-TMD 6 – with six work stations allows batch sizes of up to 18 pieces.

At this year“s IMTS Walther Trowal also displays a range of mass finishing equipment including rotary vibrators, the MV multi vib vibrators and a high-energy centrifugal disk finishing machine.

One drag finishing success story:
Polishing of the extremely wear resistant ceramic coating on orthopedic implants

One example for the successful use of the new drag finishers is a process, specifically developed by Walther Trowal, for polishing of knee femorals made from a chromium-nickel alloy, which are covered with a ceramic coating applied with a special vapor deposit method. To date these parts had to be finished manually in time consuming multiple steps with the risk of high quality fluctuations.

After a pre-grinding step the ceramic coating is polished in the new M-TMD drag finisher with a polishing medium specifically developed for this application. The result: Although the ceramic coating is extremely hard, the drag finisher produces a very smooth, shiny and highly wear resistant finish from the initially rough surface condition. The new coating extends the fatigue life of the implants from to date about 20 up to 30 years!

In developing this process Walther Trowal took an entirely new approach. Instead of using relatively soft polishing materials the company is adding an extremely hard substance to the polishing medium, namely diamond powder.

Christoph Cruse explains the advantages of the new process as follows: „Soft materials can be polished relatively easily. But the manual polishing of extremely hard coatings has been extremely difficult, especially because an even surface finish is essential for the functionality of the component. In the case of vapor deposit coating, with a layer thickness of just a few microns, it is essential not to remove too much of the coating material from the part surface. With the M-TMD drag finishing technology and the new polishing media we have resolved this difficulty: The finish is absolutely even on the entire surface area of the implants.“

Walther Trowal at the IMTS 2018
September 10 – 15, 2018, Chicago, IL, USA
North Building, Level 3, Booth 236609

The technical details

In standard drag finishers the work pieces are directly mounted to the workstations and „dragged“ through the stationary media bed producing an extremely high processing intensity. This method is more than adequate for most work pieces and produces excellent finishing results.

The new M-TMD systems allow one additional rotational movement, namely that of the spindles mounted to the workstations. The multi-spindle heads on the workstations can be also be angled allowing the adaptation of the media coverage on the work piece surface to different work piece geometries.

All process steps, from cut-down, over surface smoothing to the final polishing, take place in the same machine, without having to remove the work pieces from the spindles.

The new drag finishers are suitable for dry as well as wet processing. In wet processes for cut-down, surface smoothing and, occasionally, for polishing, special finishing compounds are used. For the targeted edge radiusing within a tolerance range of a few thousands mm, like for example for tungsten carbide drill bits or milling tools, dry grinding media are utilized. Dry processing is also used for high gloss polishing with special pastes and polishing media.

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.

Walther Trowal in America

The recently opened „Tech & Training Centre“ of the Walther Trowal LLC in Grand Rapids, Michigan has, among other equipment, a test lab for the „Trowal Coating“ technology allowing interested customers informing themselves about the most suitable coating method for their work pieces.

Trowal has also extended its presence in Latin America by recently opening a sales office in Mexico, which is, of course, using the knowhow and resources of the Grand Rapids facility.

Firmenkontakt
Walther Trowal GmbH & Co.KG
Georg Harnau
Rheinische Str. 35-37
42781 Haan, Germany
+49 2129.571-0
+49 2129.571-225
info@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

Walther Trowal opens the „North American Tech & Training Centre“

Mass finishing, deburring, polishing, shot blasting and coating: The branch in Michigan now has its own process development center and offers comprehensive service for North- and South-America

Walther Trowal opens the  "North American Tech & Training Centre"

In the Test & Training Center: Loading of work pieces into a CF rotary vibrator for processing.

To cope with the increasing business volume in the Americas and to better serve the American customers in the field of surface finishing and preparation, Walther Trowal is expanding its sales branch in Grand Rapids, established in 2005, with additional manpower and a process development lab. Recently the Walther Trowal LLC has officially opened its „North American Tech & Training Center“.

The company, initially established as a sales office, has become an operation with its own test center, after-sales service activities and a sizable warehouse for compounds, media and spare parts. Effective immediately two recently hired application and sales engineers, stationed in Grand Rapids, are now supporting the already existing nine distributors in the US and Mexico, including our sales office in Queretaro, Mexico.

Moreover, the newly established process development lab, equipped with a range of different finishing machines, now offers American customers the possibility to test the Walther Trowal equipment with their work pieces directly in the United States and to optimize their finishing processes.

Ken Raby, Vice President and General Manager of the Walther Trowal LLC, is now in a position to serve his North-American customers even better: „We consider close proximity to our customers as essential to our future success. With our expanding sales and technical base in Grand Rapids we can adapt our processes and systems much better and, especially, much faster to the requirements of the American users. Especially in the field of mass finishing it is essential to develop and optimize the various finishing processes for our customers through processing trials under manufacturing conditions in our test lab“.

The new „Tech & Training Centre“ is also equipped with a lab for coating technology. This allows the customers to test various coating methods and develop the right process for their coating requirements with the „Trowal Coating“ technology.

Christoph Cruse, general sales manager at Walther Trowal in Haan, explains why the company is expanding its presence in North-America: „The North-American market is somewhat different from Europe – Especially in the United States the automobile industry is still a key player, but is subject to enormous cost pressures. That is why it is essential for us to offer our customers fast and competent service. Long reaction or downtimes are no longer acceptable! In addition, we also see a tremendous potential in the rapidly expanding aerospace industry and medical engineering.“

In Latin America Walther Trowal has also expanded its presence with the recently opened sales office in Queretaro, Mexico. The local staff is supported by the knowhow and service of the colleagues in Grand Rapids.

The capacity of the new, large warehouse ensures that the Walther Trowal LLC can offer short delivery times for equipment and consumables. The mass finishing, shot blasting and coating equipment as well as the plastic finishing media are still supplied from the Walther Trowal headquarters in Germany. Ceramic media continue to be manufactured at the plant in Stoke-on-Trent, Great Britain.

Facts about Walther Trowal

For more than 85 years Walther Trowal has offered 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 2129.571-0
+49 2129.571-225
info@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

Walther Trowal: New Rotamat coater for small batches

Coating of mass-produced small parts: Effective coating of part batches from 2 to 15 l (0.5 to 4 gallons)

Walther Trowal: New Rotamat coater for small batches

The new Rotamat R 60 from Walther Trowal was developed for batches of up to 15 l (4 gallons)

At the PaintExpo 2018 Walther Trowal introduces the new Rotamat R 60 for coating mass-produced small parts. It allows the effective processing of small batches of, among others, metal parts with relatively high bulk weights. Even though specifically designed for small batches, the R 60 coater offers all the functional features of its larger „siblings“.

With the new Rotamat R 60 Walther Trowal is rounding off its equipment range for coating mass produced bulk parts down to very small batches. For the very first time it is now possible to effectively coat small part volumes of up to 15 liters (4 gallons).

With a drum diameter of only 600 mm (24″) this coater is ideally suited for processing small part batches like, for example, in the aerospace industry, where batch sizes rarely exceed 50 l (13 gallons). Of course, this also includes metallic work pieces with high bulk weights, which might get damaged in larger drums through the intensive part-on-part contact. These include spikes for snow tires, bullets and balancing weights.

Frank Siegel, the sales manager for „coating technologies“ at Walther Trowal can now offer the right machine for practically any coating application: „We have many customers who must coat small part batches but do not want to give up the high quality standard we achieve with our Rotamat models R 80 and R 90. With the new R 60 coater you can now effectively process small part batches without having to invest in a larger machine“.

The Walther Trowal R 60 Rotamat coater, introduced at the PaintExpo 2018 includes all the proven design features of the larger machines like the supply and exhaust air handling system, the explosion-proof LED lighting of the drum interior and the drum drive shaft mounting.

Technical details
Precise control of the supply air temperature

The temperature of the supply air is measured directly at the entry point into the drum. This is considerably more precise than the previous measuring point, where the sensor was placed at the exit of the heating unit. The result: A much more accurate control of the air temperature in the drum.

Eco-friendly operation

Like the larger models, the Rotamat R 60 incorporates a 4-stage exhaust air filtering system with a paper labyrinth filter, a filter mat and two bag filters.
Low energy consumption

Walther Trowal sized the heating unit to reflect the smaller drum diameter. This resulted in a considerably lower heat input. Depending on the physical properties of the work pieces the R 60 Rotamat can be equipped with a PID or step control of the heating unit. The result: The customers can now use coating materials, which cannot exceed or fall below certain temperatures.

Suitable for high solvent concentrations

The supply air volume in the new R 60 coater is measured with a Pitot tube. This allows the precise calculation of the solvent concentration and facilitates the certification of the machine for a high solvent throughput. This is very important for special applications like, for example, the coating of parts with an adhesion primer.

Walther Trowal at the PaintExpo 2018
17. to 20. April 2018 | Karlsruhe/Germany
Hall 2, Stand 2310

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
Frank Siegel
Rheinische Str. 35-37
42781 Haan/Germany
+49 2129.571-0
+49 2129.571-225
info@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

Walther Trowal cuts processing times for finishing of blisks from several days to a few hours

Surface finishing of components for the aerospace industry

Walther Trowal cuts processing times for finishing of blisks from several days to a few hours

The work bowl of the “CM” rotary vibrator.

For the efficient surface finishing of high value work pieces like blisks for airplane and land based turbines, Walther Trowal has redesigned its CM vibratory system. It ensures that the work pieces receive a uniform, homogeneous high quality finish with absolutely repeatable results.

The surface finish of blisks („Blade Integrated Disks“) in airplane and other turbines affects to a large extent the airflow characteristics and, thus, the overall efficiency, fuel consumption and noise emissions.

To date the surface finishing of blisks was done manually with grinding disks and other manually operated tools. Due to the „human factor“ the quality of the final finish could greatly vary between work pieces. Frequently, it could even happen that certain surface areas were not finished at all.

For the consistent and high quality finishing of circular high value components Walther Trowal redesigned the rotary vibrator „CM“ in close cooperation with leading turbine manufacturers to make it more suitable for treating all kinds of turbine components.

The „CM“ system allows deburring and general surface improvement of components with diameters of up to 980 mm.

Single work pieces are mounted to the inner dome of the processing bowl. The height of the inner dome itself has been drastically shortened. After grinding media has been filled into the bowl, a vibratory motor causes the complete work bowl to vibrate. This causes a constant „rubbing“ of the media against the fixed work piece. Since the „rubbing“ action is highly homogeneous, a uniform, even finish on all surface areas of the disk and blades is achieved. After completion of the process the surface roughness readings amount to Ra = 0.2 to 0.4 µm.

Starting with an initial surface roughness of Ra = 4 to 5 µm, the desired finishing results are achieved within about five to six hours. Compared to this innovative method the manual finishing of blisks can take several days.

Christoph Cruse, sales manager at Walther Trowal, is commenting on the special conditions prevailing in the aerospace industry: „Especially for the production of turbine components any manual manufacturing operations must be viewed with great skepticism, because the quality of the work will vary greatly. With our new finishing machine we have completely eliminated the vagaries of the human factor. And, we can reduce the finishing times for blisks from several days to just a few hours“.

For finishing of blisks Walther Trowal is recommending the special finishing media, type V 2030. This media produces very smooth surface finishes on materials and shapes, which are typical for blisks. Of course, the V 2030 media is globally approved for the aerospace industry.

Walther Trowal at Singapore Airshow, February 6 – 11 2018
Booth L82

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
Martin Huebner
Rheinische Str. 35-37
42781 Haan/Germany
+49 2129.571-209
+49 2129.571-225
m.huebner@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

Aluminum components require soft, less abrasive blast media

New blast turbines with curved throwing blades reduce cycle times.

Aluminum components require soft, less abrasive blast media

The troughed belt continuous feed shot blast machines, type THM, with curved throwing blades reduce

At the Aluminium 2016 trade show Walther Trowal introduces a new generation of blast turbines for the troughed belt continuous feed shot blast machines, type THM. These turbines increase the throwing speed and, thus, reduce cycle times for shot blasting of light metals like aluminum and magnesium. For weight reasons these two metals are increasingly replacing components, which to date were made from steel. However, shot blast applications for aluminum and magnesium frequently require soft, less abrasive blast media like, for example, aluminum shot.

When it comes to shot blasting die-castings or forged components made from aluminum and magnesium, but also zinc, many users are switching to somewhat softer aluminum blast media. Yet, because of their lower bulk density the impact energy of these media is significantly lower compared to other media like steel shot. For this reason, Walther Trowal recently developed turbines with curved throwing blades, which generate significantly higher throwing speeds.

In addition to higher throwing speeds, the new turbines also allow a much higher media throughput. Despite the lower media bulk weight of these „soft“ blast media the results are shorter cycle times an, at the same time, greatly improved surface finishes.

Since the throwing blades in the new turbines are curved on both sides, the turbines can be run in two directions.

For applications requiring steel and stainless steel blast media, Walther Trowal offers the curved throwing blades in wear resistant tool steel. This increases the overall blade uptimes significantly.

The first machine equipped with the new turbines will be delivered to a customer shortly. Of course, existing THM machines can be easily equipped with the curved blade turbines allowing the users to increase productivity and reduce their costs.

Walther Trowal at the Aluminium 2016 trade show
(Dusseldorf/Germany, November 29 – December 1, 2016):
Hall 12 / Booth G 50

Background:

Troughed belt continuous feed shot blast machines: Extremely gentle work piece transport

The THM continuous troughed belt machines can handle large quantities of bulk produced small parts as well as large, delicate single work pieces with complex shapes. Because of the much simpler and gentler work piece handling they frequently replace conventional batch tumblast machines.

THM continuous feed machines are especially advantageous for treating very delicate components: Contrary to batch tumblast systems, where the parts are intensively tumbling over each other with a high risk of nicking, in the Walther Trowal THM machines the work pieces are spread out throughout the length of the trough, ensuring a gentle, nick-free processing. The work pieces are gently rolling over the transport rods coated with polyurethane. This gentle part transport is especially important for complex, thin-walled components requiring an intensive blast cleaning process. The results are perfectly cleaned parts without any nicking or other damage.

Compared to spinner hanger machines the THM continuous shot blast systems also offer significant technical advantages. Because the work pieces are gently tumbling through the tunnel formed by the troughed belt, they are exposed to the blast stream from all sides, with the distance between work pieces and turbines remaining constant. This ensures all around, perfect shot blasting results.

Aluminum: The gentle blast media

The blast cleaning and de-flashing of die-cast or forged aluminum components requires soft blast media. Typical forged parts are steering knuckles or swivel bearings. Aluminum die-castings processed in THM systems can be housings, covers, caps and levers.

But there is also an increasing trend towards utilizing magnesium die-castings, especially in the automobile industry. Many structural components, for example dashboard mountings, are made from magnesium. This material has not only a low weight, but also offers high tensile strength.

For shot blasting of these materials in THM machines aluminum media is becoming quite popular. Since the distance between the blast turbines and the work pieces is very small, the shot blast process is highly effective, even though the blast media has a low bulk density.

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
www.vip-kommunikation.de

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

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

Walther Trowal: The rotary drum coating technology conquers the market

Homogeneous and energy saving coating of mass-produced small plastic and rubber components

Walther Trowal: The rotary drum coating technology conquers the market

Walther Trowal introduces the new Rotamat R80 at the DKT exhibition.

More and more customers are choosing the rotary drum technology for coating their mass-produced small plastic and rubber components. Within just a few years the sales of the Walther Trowal Rotamat coating systems have increased several fold. At the DKT/IRC 2015 the company is introducing its redesigned Rotamat R80, which compared to its predecessor model offers not only a higher operational flexibility but also a higher capacity for coating of plastic components.

For several months now Walther Trowal has noticed a distinct trend towards the use of rotary drum coaters for the coating and painting of small mass-produced components. Many small-part manufacturers are switching from the drum coating at room temperature to the hot air drum coating technology. Other manufacturers are no longer subcontracting their coating work to external service companies but do it in-house with Rotamat systems. And some have replaced their single-piece paint systems with rotary hot air drum coaters.

With the drum coating method the small parts no longer have to be individually placed on special racks but can be loaded into the Rotamat drum in relatively large batch sizes. This technology is ideally suited for treating small parts made from different plastic materials like elastomers, ABS, PC or PS. Water based as well as solvent based paints can be processed.

Building on the success of the predecessor models Walther Trowal completely revamped the Rotamat range, and with the R80 is introducing a machine that can be even better adapted to the individual requirements of the users. The modular filtering system allows not only cleaning the exhaust air up to filter class F6, but it also allows spraying more solvent based paint, offering a higher part throughput without jeopardizing compliance with the prevailing clean air standards.

Frank Siegel, the sales manager for coating technology at Walther Trowal, explains, why the sales of Trowal coating systems are continuously increasing: „Since the Rotamat was introduced, we have sold nearly 300 units. The increased machine bookings we have seen during the past few months are mainly due to the fact that many small-part manufacturers are bringing their coating work back in-house to reduce their costs and, at the same time, improve their quality.“

Many new technical features!

The new Rotamat R80 from Walther Trowal has a drum diameter of 800 mm and can handle about 50 kg of parts with a batch volume of 50 liters. This batch size meets the requirements of many customers who must coat delicate, complex shaped parts or are processing relatively heavy parts like metal components. The new R80 is also available with a drum that offers a diameter of 700 mm and a usable part volume of 30 liters.

The airflow and the paint application system were optimized to a point where only a very small amount of overspray is created.

The inside of the coating drum is equipped with an explosion protected LED light allowing precise observation of the coating process, be it the paint layer buildup or color changes.

The new heating control system helps reduce cycle times and energy consumption. A PID controller adjusts the inlet air temperature in relation to the work piece temperature. At the same time it takes into consideration the actual air volume. The new controller reacts extremely quickly. This quick reaction and the better insulation of the drum allowed reducing the electrical energy requirements to 9 kW.

Air filtration

With the new exhaust air filter unit Walther Trowal managed to greatly enhance the possibility for using different paints. This is an important feature for those customers who must coat a large variety of parts with different types of paint. The R80 offers four independently usable stages for filtering the exhaust air so that the particle sizes caught by the filter system can vary within a relatively large range up to filter class F6.

The new filter unit also contributes to a higher part throughput: The user can now use more solvent, thus, speed up the coating process and still meet the standards for the maximum solvent concentration at the work place.

Another important feature of the new filtration system is the secondary air system that allows the connection to a thermal post combustion installation, which may be already available at the customers. The secondary air system limits the air volume pulled by the thermal post combustion installation so that the coating process is not affected.

Walther Trowal at the DKT/IRC 2015
(June 29 – July 2, 2015 in Stuttgart):
Hall 12, Booth 260

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.

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
Süsterfeldstrasse 83
52072 Aachen/Germany
+49.241.89468-24
reinhardt@vip-kommunikation.de
http://www.vip-kommunikation.de

Walther Trowal: The rotary drum coating technology conquers the market

Homogeneous and energy saving coating of mass-produced small plastic and rubber components

Walther Trowal: The rotary drum coating technology conquers the market

Walther Trowal introduces the new Rotamat R80 at the DKT exhibition.

More and more customers are choosing the rotary drum technology for coating their mass-produced small plastic and rubber components. Within just a few years the sales of the Walther Trowal Rotamat coating systems have increased several fold. At the DKT/IRC 2015 the company is introducing its redesigned Rotamat R80, which compared to its predecessor model offers not only a higher operational flexibility but also a higher capacity for coating of plastic components.

For several months now Walther Trowal has noticed a distinct trend towards the use of rotary drum coaters for the coating and painting of small mass-produced components. Many small-part manufacturers are switching from the drum coating at room temperature to the hot air drum coating technology. Other manufacturers are no longer subcontracting their coating work to external service companies but do it in-house with Rotamat systems. And some have replaced their single-piece paint systems with rotary hot air drum coaters.

With the drum coating method the small parts no longer have to be individually placed on special racks but can be loaded into the Rotamat drum in relatively large batch sizes. This technology is ideally suited for treating small parts made from different plastic materials like elastomers, ABS, PC or PS. Water based as well as solvent based paints can be processed.

Building on the success of the predecessor models Walther Trowal completely revamped the Rotamat range, and with the R80 is introducing a machine that can be even better adapted to the individual requirements of the users. The modular filtering system allows not only cleaning the exhaust air up to filter class F6, but it also allows spraying more solvent based paint, offering a higher part throughput without jeopardizing compliance with the prevailing clean air standards.

Frank Siegel, the sales manager for coating technology at Walther Trowal, explains, why the sales of Trowal coating systems are continuously increasing: „Since the Rotamat was introduced, we have sold nearly 300 units. The increased machine bookings we have seen during the past few months are mainly due to the fact that many small-part manufacturers are bringing their coating work back in-house to reduce their costs and, at the same time, improve their quality.“

Many new technical features!

The new Rotamat R80 from Walther Trowal has a drum diameter of 800 mm and can handle about 50 kg of parts with a batch volume of 50 liters. This batch size meets the requirements of many customers who must coat delicate, complex shaped parts or are processing relatively heavy parts like metal components. The new R80 is also available with a drum that offers a diameter of 700 mm and a usable part volume of 30 liters.

The airflow and the paint application system were optimized to a point where only a very small amount of overspray is created.

The inside of the coating drum is equipped with an explosion protected LED light allowing precise observation of the coating process, be it the paint layer buildup or color changes.

The new heating control system helps reduce cycle times and energy consumption. A PID controller adjusts the inlet air temperature in relation to the work piece temperature. At the same time it takes into consideration the actual air volume. The new controller reacts extremely quickly. This quick reaction and the better insulation of the drum allowed reducing the electrical energy requirements to 9 kW.

Air filtration

With the new exhaust air filter unit Walther Trowal managed to greatly enhance the possibility for using different paints. This is an important feature for those customers who must coat a large variety of parts with different types of paint. The R80 offers four independently usable stages for filtering the exhaust air so that the particle sizes caught by the filter system can vary within a relatively large range up to filter class F6.

The new filter unit also contributes to a higher part throughput: The user can now use more solvent, thus, speed up the coating process and still meet the standards for the maximum solvent concentration at the work place.

Another important feature of the new filtration system is the secondary air system that allows the connection to a thermal post combustion installation, which may be already available at the customers. The secondary air system limits the air volume pulled by the thermal post combustion installation so that the coating process is not affected.

Walther Trowal at the DKT/IRC 2015
(June 29 – July 2, 2015 in Stuttgart):
Hall 12, Booth 260

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.

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
Süsterfeldstrasse 83
52072 Aachen/Germany
+49.241.89468-24
reinhardt@vip-kommunikation.de
http://www.vip-kommunikation.de

Walther Trowal offers more reliable finishing results

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

Walther Trowal offers more reliable finishing results

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

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