Automotive Engine & Powertrain Components Manufacturer

Client Profile

Business Challenge

The client had some issues with their cleaning and surface finishing process, which couldn't guarantee both the cleanliness and the cosmetic finish:

• Residual Oil & Grease: The conventional washing systems were not able to completely remove the oil from the pores and textured surfaces of the castings.
• Uneven Appearance: Steel shot blasting resulted in a dull and inconsistent finish, especially on the aluminum parts of the engine.
• Manual Touch-Up: Operators often ended up hand cleaning and doing cosmetic corrections, which increased cycle time and variability.
• OEM Rejections: Failures in visual inspection due to stains, blotchy finish, and surface marks caused shipment delays.
• High Maintenance: Use of aggressive abrasives led to excessive wear of blast equipment and generated high levels of dust.

Solution Implemented

After analyzing the type of material, the level of oil contamination, and the expected final finish, we suggested using Glass Beads blasting as a single cleaning and cosmetic finishing method.

Specific Solution:

• High-quality spherical Glass Beads (180–300 microns) that are suitable for oily cast and machined engine components.

Process Customization:

• Fine-tuning blasting pressure to effectively disrupt oil films without contaminant embedding.
• Modifying the media flow and dwell time to achieve uniform coverage on complex geometries and internal surfaces.
• Combining pre-drip oil removal and post-blast air cleaning to further improve the process efficiency.

Application Objective:

• Eliminate oil, coolant residues, and light oxidation
• Generate a clean, bright, and visually uniform surface
• Enhance surface appearance without changing casting texture or ​‍​‌‍​‍‌​‍​‌‍​‍‌dimensions

Implementation Process

Timeline: ​‍​‌‍​‍‌​‍​‌‍​‍‌ six weeks from trials till production stabilisation.

Deployment Steps:

• Week 1: Testing components such as cylinder heads, gearbox housings, and covers with oily surfaces.
• Week 2: Completing the steel shot vs. Airo Shot Blast Equipments blasting comparison.
• Week 3: Adjustment of bead size, blasting conditions, and formulation of SOPs.
• Week 4: Conversion of the blast machine and improvement of the dust collection system.
• Week 5: Production line operator training and launch.
• Week 6: Process stabilization and OEM sample approval.

Training sessions covered media cleanliness, oil management, and finish consistency control for operators and maintenance staff.

Results & Impact

Changing to glass beads, the company experienced significant benefits in all the quality, productivity, and cost areas:

• Higher Cleanliness Level: Complete elimination of oily residues even from the microscopic pores and edges of the surface.
• Shiny Cosmetic Finish: A Bright, consistent look was obtained on both the aluminum and cast-iron parts.
• Lowered Manual Work: Resulted in more than 60% less hand cleaning and cosmetic touch-ups.
• OEM Acceptance: Rejections based on visual inspection were decreased from 9% to a level lower than 1%.
• Cleaner Operation: Less generation of dust and therefore less wear and tear of the blast system components.

ROI & Business Benefits

• Reduced Consumable Costs: Use of glass beads for a longer duration as compared to steel shots under oily conditions.
• Labor Optimization: Less manual cleaning and rework.
• Improved Throughput: The finishing operation cycle time was cut down by nearly 30%.
• Payback Period: It is figured at 8–10 months, mainly due to fewer rejections and labor savings.

Why the Client Chose This Company

The client's choice was based on our:

• Automotive Process Expertise: Deep knowledge of OEM cleanliness and visual standards.
• Trial-Oriented Approach: Process parameters verified on real, oily production parts.
• End-to-End Support: Media selection, machine tuning, and post-installation support.
• Reliable Media Quality: Consistent Airo Shot Blast Equipments sizing ensured repeatable results across ​‍​‌‍​‍‌​‍​‌‍​‍‌shifts.