Based in Rushville, Indiana, Intat Precision Inc. produces ductile iron automotive components on three DISAMATIC molding lines. But on two of its lines, batch loading, unloading and sorting for shot blasting ate up labor, storage space and energy, with high abrasive consumption adding further cost. The maintenance-heavy barrel blasting machines also took up valuable floor space.
“We knew continuous technology would increase our throughflow, so we went to visit MTI in Auburn and saw the CT machine in action,” says Neil Gross, VP of Manufacturing at Intat. “Wheelabrator’s quality was a driver and, as it’s part of Norican, we knew we’d get the same reliable machines and solid support we already have with DISA, Simpson and Monitizer.”
Completely automated blasting is a gamechanger
Easily integrated into existing production lines, the CT’s clever tumblast design makes sure that every part turns over completely to clean inside and out, ideal for cored castings. It automatically adjusts throughput speed and abrasive flow to cope with varying workloads and mixed runs, maximizing throughput while maintaining quality. Other cost-reducing CT advantages include zero intermediate storage requirements, short transport distances, and little or no need for manual part handling.
After a seamless installation in mid-2024, the single Wheelabrator machine is coping effortlessly with Intat’s production of at least 240 cored/300 uncored castings per hour across two DISAMATIC lines. There’s no more shuttling or strenuous manual part separation to segregate products for different machines, and the CT3’s higher surface quality has completely cut out reblasting. Its dust-free operation has removed airborne silica while the machine’s compact footprint is perfect for Intat’s space-constrained facility.
Less manual labor for faster, safer, lower-cost cleaning
“The big win for us was definitely the reduction in labor cost and the labor required to blast and stage castings,” says Neil. “We’ve been able to stop handling heavy, sand-covered castings. Any handling is post-blast now and our operators no longer have to wear respirators.”
With operators hard to find in rural Indiana, Intat now has a smaller, less fatigued shot blasting crew—lowering labor costs, enhancing safety and, with a single machine, simplifying training. The CT3’s low maintenance and higher uptime further reduce labor costs, especially expensive overtime. Energy use is down too. Freeing up internal floorspace for storage made the external warehouse unnecessary, reducing costs further.
“The Wheelabrator equipment has worked flawlessly, easily keeping up with our production and significantly reducing downtime and handling,” says Neil. “The CT3 has cut our re-blasting, abrasive and energy consumption way down, along with labor costs and maintenance. Plus our operators are happy to have an easier job in a much cleaner, safer working environment. That’s why we are considering another just like it.”
More about Wheelabrator CT: https://www.wheelabratorgroup.com/equipment/wheelblast-machines/tumblast-machines/ct-continuous-tumblast-machine
About Wheelabrator
Founded in 1908, Wheelabrator is a global pioneer in shot blast technology, offering a comprehensive portfolio of wheelblast and airblast equipment solutions to customers in automotive, foundry, aerospace, construction, and beyond. The brand is part of Norican, alongside molding technology leader DISA, foundry sand expert Simpson, aluminum furnace specialist StrikoWestofen, and IIoT brand Monitizer.
