See how our separation systems delivered measurable improvements in efficiency, cost reduction, and operational performance across major industries.
Precision Surface Preparation
Major aerospace manufacturer producing precision aircraft components required absolute contamination control and strict aerospace quality specifications (AS9100). Current separation system insufficient for cleanliness requirements.
Three-stage separation system combining air wash primary, cyclone secondary, and magnetic final stage. Integrated with enhanced dust collection. Implemented continuous quality monitoring with automated data logging.
Media Cost Reduction: 72%
Recovery Rate: 97-99%
Contamination Removal: 99.8%
Payback Period: 8 months
Annual Savings: $3.2M
✓ Exceeds aerospace foreign particle detection limits (<0.1%)
✓ AS9100 compliant operation
✓ Complete traceability and documentation
✓ Quality improvement recognized by customers
Media Recycling & Sand Recovery
Large iron foundry producing 500 tons/day of castings required improved sand recovery and media recycling. Manual processes inefficient, material waste excessive, casting quality variable.
Integrated multi-stage system with vibratory screening for size classification, air wash for contamination removal, and pneumatic conveying to centralized reclaim. Magnetic separation for metal capture. Automated operation with minimal labor.
Processing Time: 58% reduction
Media Recovery: 92-95%
Casting Quality: Improved 35%
Labor Reduction: 4 FTE savings
Annual Savings: $2.8M
✓ Automated 24/7 operation
✓ Consistent sand quality
✓ Reduced casting defects
✓ Improved production throughput
Blast Room Recovery Systems
Large shipbuilder processing 100+ tons/day of structural steel for surface preparation and coating removal. Massive waste disposal costs, inconsistent surface profile, limited blast room uptime.
Large-scale closed-loop system with dual air wash separators, dual cyclone pre-separators, and comprehensive dust collection. Material handling from blast room through reclaim to storage silo with continuous operation capability.
Waste Reduction: 65%
Media Recovery: 90-98%
Blast Room Uptime: +40%
Payback Period: 14 months
Annual Savings: $4.2M
✓ Eliminated blast room constraints
✓ Consistent surface profile quality
✓ Sustainable operations
✓ Environmental responsibility demonstrated
High-Volume Metal Finishing
Automotive parts manufacturer processing 80 tons/day of engine blocks and transmission cases. Rising material costs, variable quality, high dust generation affecting worker health.
Dual air wash separators with secondary cyclones for high-volume processing. Integrated pneumatic conveying and automated silo management. Enhanced dust collection with HEPA filtration for worker protection.
Material Cost Reduction: 68%
Recovery Rate: 92-96%
Air Quality: OSHA compliant
Payback Period: 10 months
Annual Savings: $3.6M
✓ High-volume consistency
✓ Improved worker safety
✓ Environmental compliance
✓ Scalable for facility growth
Proper system engineering optimized for specific media types and contamination profiles. Not generic solutions, but engineered for success.
Professional installation, operator training, and startup optimization ensure systems operate at design specifications from day one.
Continuous support, maintenance programs, and optimization ensure sustained performance and maximum ROI throughout system life.
Every system achieves documented improvements in cost, efficiency, and quality. Real numbers, real results, real ROI.
Deep understanding of aerospace, automotive, foundry, and shipbuilding requirements ensures solutions meet specific industry needs.
Systems exceed standard specifications and support advanced quality standards including aerospace and automotive certifications.
See how our separation systems can transform your operations. Contact our engineering team for a consultation tailored to your specific challenges and opportunities.