E-Archive
Articles
in Vol. 26 - January Issue - Year 2025
Achieving Precision: Helping a Steel Shot Producer Meet Strict Quality Standards

Static Spiral Separators Installation

One-core Powered Spiral Separators - the Solution


Tommy Saatzer

The Profile Industries Team Based in Rogers, MN, USA
Steel shot production is a demanding process. Every shot plays a critical role in applications like abrasive blasting and shot peening, where the performance of the shot is directly tied to its roundness. A perfectly round shot ensures consistency, efficiency, and reliability - qualities that end-users demand.
One steel shot producer came to us with a challenge: their current sorting process wasn’t delivering the level of precision their customers required. Too many irregularly shaped particles passed through, which affected product performance and put their reputation on the line.
They needed a better way to ensure their steel shot met strict roundness standards. It had to be accurate, efficient, and reliable enough to integrate seamlessly into their production line. After assessing their needs, we knew our Powered Spiral Separator would be the right tool for the job.
The Challenge: Delivering Consistency in a Demanding Market
The steel shot producer faced a common but critical issue in their industry: maintaining consistent quality at scale. Their shot had to be as close to perfectly round as possible, or it wouldn’t perform as expected.
Irregular shot causes uneven wear, inefficiencies, and unpredictable results. For applications like shot peening, where precision strengthens critical components, even small inconsistencies can have serious consequences.
Their existing sorting methods weren’t cutting it. Traditional systems were labour-intensive, prone to frequent failures, and allowed imperfections to slip through. What’s worse, these methods often resulted in over-sorting, discarding usable shot and increasing waste. They needed a solution that would provide better results with less hassle.
The Solution: Introducing the Powered Spiral Separator
The Powered Spiral Separator provided exactly what they were looking for: a reliable, efficient, and precise way to sort their steel shot.
This system uses centrifugal force and gravity to sort particles based on their shape and density. Round particles naturally roll off the spiral flight, while irregular shapes are separated out. This approach is simple in principle but highly effective in practice, particularly for materials like steel shot, where even small imperfections matter.
We worked closely with the producer to ensure the separator fit seamlessly into their existing process. Its compact design meant it didn’t require a large footprint, and its low-maintenance operation reduced downtime. The result? A system that worked hard behind the scenes to deliver consistently high-quality output.
The Results: Precision, Efficiency, and Peace of Mind
Once the Powered Spiral Separator was up and running, the producer saw a significant change in their operation. Compared to the older spiral separators they had been using, the new Powered Spiral Separator increased the number of round materials sorted from their production line by 30%. This improvement directly addressed their need for higher precision and efficiency.
Here’s how it made a difference:
1. Consistent Roundness: The Powered Spiral Separator delivered steel shot that consistently met their customers' stringent roundness standards. Its precise sorting process effectively removed irregular particles, ensuring only the best materials reached their customers.
2. Increased Efficiency: With its high throughput, the Powered Spiral Separator allowed the producer to process more materials in less time. This 30% boost in sorting precision enabled them to meet growing demand without compromising on quality.
3. Reduced Waste: The improved accuracy of the Powered Spiral Separator minimised the number of usable materials mistakenly discarded, significantly reducing waste. This not only saved on production costs but also made their process more sustainable.
4. Lower Maintenance: Unlike their previous systems, which were prone to frequent failures and required constant attention, the Powered Spiral Separator ran with minimal upkeep. This reliability allowed the team to focus on other aspects of production, reducing downtime and overall operating costs.
This 30% improvement in sorting precision was a game-changer for their operation, enabling them to deliver a higher-quality product while operating more efficiently and sustainably.
Building Confidence in Their Product
For this steel shot producer, integrating the Powered Spiral Separator wasn’t just about solving a sorting problem - it was about improving their product and their reputation. By delivering consistently high-quality steel shot, they strengthened their relationships with customers and built trust in their ability to meet demanding standards.
At Profile Industries, we understand that for our customers, precision isn’t optional - it’s essential. That’s why we’re committed to providing tools and solutions that help businesses like this steel shot producer achieve their goals.
If you’re facing similar challenges in your production process, we’re here to help. Let’s work together to find the solution that takes your quality, efficiency, and customer satisfaction to the next level.
Business Development Manager of Profile Industries
For Information:
Profile Industries 14200 James Road Rogers, MN 55374, USA
Tel. +1.763.428.5858
E-mail: info@profile-ind.com
