Revving up production manufacturing turbochargers

The Wheelabrator Group has provided a range of new surface preparation and finishing equipment at the turbocharger manufacturer and reconditioner, Holset Engineering

The surface preparation and cleaning technology experts, the Wheelabrator Group, have provided a range of new surface preparation and finishing equipment to turbocharger manufacturer and reconditioner, Holset Engineering.

A new vibratory bowl machine, three table type blasting machines, two basket type washing machines and six ultrasonic cleaning systems will allow the customer to carry out a complete cleaning, peening, washing and vibratory finishing process at its reconditioning facility in Huddersfield.

In addition to manufacturing, Holset reconditions a range of turbochargers for medium and heavy duty diesel engines for highway applications including trucks and buses, as well as for power generation and marine use.

With more than 120 units already processed each week, the company needed to increase throughput of reconditioned turbochargers to accommodate its growing order book.

Simon Brierley, remanufacturing team leader at Holset said: "Combined with an extension in our operating hours, these machines have allowed us to increase throughput to around 220 units a week, an increase of more than 80 per cent.

"The machines have helped us to achieve a more efficient production line with parts now only taking four days from strip to rebuild.

In particular, the six ultrasonic machines are extremely effective at removing oil and carbon residues from the aluminium components, leaving them in an optimum condition ready for shot blasting and, as a result, this has reduced the blasting time needed".

On arrival, the turbochargers for refurbishing are stripped and the components cleaned.

Aluminium components are placed in the six S6090 ultrasonic systems from Clean-Tek and delicate nozzles are processed in the CD 200 vibratory finishing machine, part of Wheelabrator Walter Trowal product range, to remove carbon deposits and improve the surface finish.

Following this, cast iron and aluminium components are shot blasted in one of two MT1000 and one RT1000 table-type machines from Spencer Halstead and Tilghman Wheelabrator, applying the high quality finish required to comply with detailed manufacturing specifications.

This type of machine provides effective cleaning for difficult parts with high edges or deep pockets, such as rotators, and can handle fragile and thin-walled parts without damage.

Finally Holset uses the two B100 basket-type aqueous wash machines from Clean-Tek to clean the components before they are reassembled, ready to be packed and shipped to customers.

Prior to this recent installation, Holset had existing shot-blast machinery from the Wheelabrator Group in its manufacturing facility and had been impressed by the level of service it received.

The Wheelabrator Group is the world-leading designer and manufacturer of wheelblast, airblast and mass finishing equipment for surface preparation and cleaning, and serves a range of sectors, including the aerospace and automotive industries.

Nigel Buffham, area sales manager at Wheelabrator Group, said: "Holset required a complete solution that would add value to its reconditioning process.

With seven brands and an extensive product range, we had a wealth of machines within the group from which to select the most appropriate package.

"These machines are allowing Holset to increase throughput and enhance its production process, giving it a strong foundation for future growth." The Wheelabrator Group equipment, which ranges from simple to highly sophisticated, is used for the pre-treating, conditioning, preparing, finishing and post-manufacture finishing of mainly metal components.

Its core products include wheel, air and wet type blast machines, as well as mass finishing equipment, washing, degreasing, and ultrasonic cleaning systems.

It also supplies blast media, spares, and consumables and has companies dedicated to sub contract services.

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