Winter can be a challenging time for companies using shot blasting to prepare or clean metal surfaces. As the weather turns colder, nights grow longer, and production schedules are often interrupted by seasonal breaks, operators may encounter specific issues that impact efficiency, equipment health, and product quality. Two challenges in particular—restarting equipment after extended downtime and managing moisture in the abrasive operating mix—can cause significant disruptions if not addressed proactively.

With careful planning and attention to detail, these seasonal issues can be mitigated. Drawing on years of experience in shot blasting operations, here are some practical tips and expert advice to keep your winter operations running smoothly.

One of the most common winter challenges is restarting equipment after longer-than-usual production pauses, such as a Christmas shutdown. Machines that have been idle for days or weeks require a systematic inspection before restarting to prevent unexpected downtime or equipment damage.

Mechanical and electrical checks, as recommended by your machine manufacturer or outlined in your maintenance protocols, should form the foundation of your restart procedure. Special attention should be given to the operation of blast wheels, air nozzles, and the abrasive media transportation system. At start-up, there should not be large quantities of abrasive in these systems, as this can cause blockages or uneven wear.

The abrasive itself and its recycling system also need inspection. Remove any clusters caused by moisture, check that the hopper is at least three-quarters full, and use a mixture of new and reclaimed abrasive if possible. If only new abrasive is available, allow a run-in period to achieve normal performance. Sieves, air wash separators, ducting, filters, and dust collectors should all be checked and cleaned if needed.

A newly restarted machine should be closely monitored, with scheduled production checks in place. These steps not only help meet production targets quickly but also minimize health and safety risks and prevent costly damage to equipment.

Quick Tip: Always plan your restart checklist in advance and assign responsibility for each step—small oversights can lead to significant production delays.

Moisture is another seasonal challenge that can affect shot blasting performance during winter. Workpieces stored outdoors, combined with higher humidity and colder temperatures, increase the risk of moisture entering the abrasive operating mix. Wet steel abrasive tends to stick together in the blast pot, hopper, elevators, and reclaiming system. Breaks in production make this worse, leaving abrasive difficult to move and separate effectively.

The consequences are significant: reduced productivity, inconsistent blasting quality, poor coating results, and additional strain on filter units. Winter conditions exacerbate these issues, making proactive moisture management essential. In a worst-case scenario, the abrasive can become completely solid when wet, requiring a full evacuation and replacement of the hopper’s contents.

A practical solution is incorporating a mineral additive such as Amapure, which not only reduces oil and grease in the process but also absorbs moisture in the abrasive mix. This helps keep the abrasive free-flowing and maintains consistent performance, even when temperatures drop and environmental moisture rises. Operators will notice improved blasting quality, fewer blockages, and less stress on filters, making winter operations far more predictable.

Paul Abram, Ervin Technical Director, commented: “Moisture in the abrasive mix is a hidden winter challenge that can affect both blasting quality and equipment health—addressing it early with Amapure makes all the difference.”

Quick Tip: Store abrasive in a dry, controlled environment wherever possible, and top up hoppers with a balanced mix of new and recycled abrasive to reduce the risk of moisture-related problems.

Combining careful restart procedures with proactive moisture control creates a strong foundation for winter shot blasting success. However, it is equally important to monitor the system continuously and adjust as conditions change.

Regularly check abrasive flow, hopper levels, and machine components throughout the day. Winter conditions can vary from week to week, and staying vigilant ensures that minor issues do not escalate into costly downtime. Adjusting airflow, checking air wash efficiency, and monitoring filter performance are small steps that can have a major impact on overall productivity.

From a broader perspective, addressing these two winter challenges demonstrates a proactive approach to shot blasting management. Not only does it protect equipment and maintain output, but it also reinforces a culture of operational excellence.

Quick Tip: Consider documenting lessons learned from each winter season. Over time, this creates a tailored playbook for maintaining performance in cold weather that can be shared across multiple facilities.

Winter need not be a season of reduced performance or unexpected headaches for shot blasting operations. By focusing on two key areas—restarting equipment after production pauses and managing moisture in the abrasive mix—companies can maintain consistent productivity, protect their equipment, and deliver high-quality results. Combining careful inspections, additive solutions such as Amapure, and vigilant monitoring allows operators to navigate seasonal challenges with confidence, keeping shot blasting operations efficient and reliable even in the coldest months.

As Paul Abram says: “Winter need not be a season of reduced performance—with the right preparation, shot blasting operations can remain efficient and reliable.”

For Information: 

Ervin Germany GmbH

Rudower Chaussee 48 

12489 Berlin, Germany

Tel. +49.30.400 37846

E-mail: info@ervin.eu

www.ervin.eu