Rösler Smart Solutions Service Digitizes, Enhances Mass Finishing and Shot Blasting Processes

Rösler has developed Rösler Smart Solutions (RSS), a service designed to digitize and enhance mass finishing and shot blasting processes. The RSS is a smart, adaptive solution that integrates digital technologies into existing manufacturing processes, making them more transparent, efficient and responsive.

The RSS provides real-time data on operational parameters, enabling immediate responses to any deviations or equipment faults. This active monitoring is designed to ensure that issues are detected early, thereby preventing costly downtimes and production halts. With detailed insights into machine performance and process parameters, manufacturers can optimize resource use, reduce waste and lower operational costs.

“At its core, RSS is about unlocking the potential of your existing equipment through digitization,” says Chris Kershaw, automation and retrofit manager at Rösler UK. “By implementing RSS, manufacturers can achieve significant cost savings and efficiency improvements. The service offers a comprehensive digitization package that enhances process transparency and operational control.”

One of the feature highlights of RSS is its focus on predictive maintenance. By continuously monitoring equipment health and performance, RSS can predict when maintenance is needed, reducing unexpected breakdowns and extending the life span of machinery. This proactive approach minimizes downtime and ensures consistent production quality.

“RSS has demonstrated a transformative impact on mass finishing by improving the management of process water cleaning and recycling,” Kershaw says. “The digital process water management software allows precise monitoring of up to 13 parameters, such as compound concentration and pH levels, issuing corrective recommendations to maintain process stability. RSS reduces rework and scrap by up to 50%, ensures higher quality finishes and educates operators on process intricacies, thereby enhancing both efficiency and ecological sustainability in mass finishing applications.”

RSS for shot blasting includes live data monitoring, quick fault response, intelligent controls and optimized resource use. The package covers all shot blast machines with customizable hardware and software modules focused on workpiece quality, operating parameters and maintenance. Benefits include consolidated performance metrics, active monitoring of consumptive values, preventive maintenance tracking and automated spare part ordering, all aimed at optimizing operations and reducing operating costs.

Beyond immediate economic benefits, RSS also supports sustainable manufacturing practices. By optimizing processes and reducing energy consumption, RSS contributes to a smaller environmental footprint.

“In an era where digital transformation is no longer optional but essential, Rösler Smart Solutions stands out as a pivotal service for manufacturers,” Kershaw says. “By digitizing and optimizing mass finishing and shot blasting processes, RSS delivers unparalleled transparency, efficiency and cost savings. For manufacturers looking to stay competitive and sustainable, embracing RSS is a step towards a smarter, more efficient future.”