Rösler can significantly reduce costs, enhance production efficiency, and ensure consistent quality in high-tech manufacturing through its advanced automation and surface treatment technologies.
In a significant step towards enhancing cost-efficiency and competitiveness, Schaltbau GmbH has successfully automated the de-flashing of plastic housings at its Aldersbach facility in Bavaria (Germany), using advanced shot blast technology from Rösler Oberflächentechnik GmbH. The investment has enabled the company to reduce personnel requirements by approximately 40–50%, underscoring the strategic value of industrial automation.
A global leader in electromechanical components for the safe switching and protection of direct current (DC) applications, Schaltbau GmbH produces a wide range of high-performance products under the Eddicy brand. These solutions, serving sectors such as energy and electric vehicles, are manufactured across multiple sites in Germany, Europe, the United States and Asia.
Faced with the challenge of rising labour costs and increasing global competition, Schaltbau’s operations team at Aldersbach initiated a lean manufacturing project focused on identifying cost-saving opportunities. A key area identified was the manual de-flashing of plastic housing components, which until then required significant staffing, with one operator assigned to each press.
The company sought a gentle, efficient, and ATEX-compliant solution that could automate this labour-intensive process
without compromising product quality. After evaluating multiple suppliers, Schaltbau selected Rösler, a long-standing partner known for its expertise in surface finishing technologies.
The chosen solution, Rösler’s RSAB 370-T1+1 wire mesh belt blast machine, stood out for its innovative design and performance during extensive processing trials. Designed specifically for treating plastic components, the RSAB 370-T1+1 uses two specially developed W32 turbines positioned above and below a 370 mm-wide wear-resistant wire mesh belt. The components—measuring up to 350 x 215 x 45 mm and weighing up to 575 grams—are placed manually on the belt and transported at speeds customised to their characteristics and de-flashing requirements.
Polyamide pellets serve as the blast media, reaching all sides of the components thanks to the belt’s open structure. A powerful dust extraction system, along with a dual-stage blow-off system, ensures the components emerge clean and free from residue.
The machine also features an integrated blast media cleaning system with vibratory screening, an air-wash separator, and automatic media replenishment to maintain optimal processing conditions. In line with ATEX safety regulations, the system includes an anti-static device with automatic compound dosing and a compliant dust collection unit to minimise fire and explosion risk. To further enhance the working environment, Rösler supplied a customised noise-reducing cabin for the entire machine, and extended the wire mesh belt to compensate for the reduced loading area caused by the enclosure.
So, thanks to Rösler’s cutting-edge blasting technology, Schaltbau has achieved a remarkable 40% reduction in personnel requirements for the de-flashing process.