Shot Blasting Complex for a Machine-Building Enterprise

The core of the complex is a closed shot blasting chamber with a working area of 6,000 × 3,000 × 3,000 mm, designed for processing large metal products under controlled conditions. The chamber structure is based on a metal frame with metal profile cladding and an internal protective lining that ensures resistance to abrasive media.

Sliding gates measuring 3,000 × 2,000 mm are provided for loading products, while a separate service door measuring 840 × 1,975 mm is provided for personnel access. The working area is illuminated by LED luminaires with impact-resistant glass, providing adequate illumination in the dusty environment inside the chamber.

The chamber is integrated with the mechanised abrasive collection system, the filtration and extraction unit and the centralised control system. For safe operation, interlocking is provided that stops the equipment when the gates or the service door are opened.

To ensure continuous operation of the complex, the KASO chamber is equipped with an automated abrasive collection and regeneration system. The system provides a closed-loop cycle of abrasive use: spent shot is automatically collected, conveyed, separated from dust, scale and other contaminants, stored in a hopper and returned to the blasting process.

This approach reduces abrasive consumption, minimises manual operations and maintains consistent cleaning quality of metal products throughout the operating cycle of the complex.

Scraper Conveyor (Scraper Floor)

One of the key elements of the complex is the mechanised scraper floor, designed for automatic collection of spent abrasive media across the entire chamber floor. The structure consists of floor gratings and a system of longitudinal and transverse channels in which the scraper conveyors are located.

During operation, shot, scale and other particles generated in the cleaning process fall through the floor gratings into the transport channels. The scraper conveyors automatically move the collected material to the receiving unit of the regeneration system.

The use of a scraper floor keeps the working area clean, eliminates the need for manual abrasive collection and ensures continuous operation of the complex with automated return of usable shot into the process cycle.

Bucket Elevator

The bucket elevator provides vertical transport of abrasive media from the collection system to the separation unit. After the spent shot arrives from the scraper floor, the abrasive enters the receiving hopper of the elevator, from where it is lifted to the required height by means of buckets.

In the upper part of the elevator the abrasive is fed to the separator, where reusable abrasive is separated from dust, scale and other contaminants. This arrangement automates the transfer of shot between the main units of the complex and ensures continuous operation of the regeneration system.

The use of a bucket elevator in the KASO complex minimises manual operations, ensures a stable supply of abrasive media to the separator and is an important component of the closed-loop reuse cycle of the shot.

Abrasive Media Separator

The separator is a key element of the abrasive regeneration system and is designed for cleaning spent shot before its reuse. After being fed by the bucket elevator, the abrasive media enters the separator, where reusable abrasive is separated from dust, scale and other contaminants.

During separation, dust, scale, coating particles and other foreign inclusions generated in the product cleaning process are removed from the abrasive stream. The cleaned shot enters the storage hopper and is reused in the blasting equipment, while light impurities are directed to the filtration system.

The use of a separator maintains consistent abrasive quality, reduces its losses and ensures efficient operation of the shot blasting complex in continuous-cycle mode.

Shot Storage Hopper

The storage hopper is the final element of the abrasive regeneration system and is designed for storing cleaned shot before it is re-supplied to the blasting equipment. After separation, usable abrasive accumulates in the hopper, providing a continuous reserve of material for uninterrupted operation of the complex.

The use of the hopper stabilises the abrasive supply during the cleaning process, compensates for short-term fluctuations in material consumption and maintains uniform operation of the regeneration system. The unit is integrated with the bucket elevator, separator and blasting equipment, forming a single closed-loop abrasive use cycle.

In combination with the automated collection and cleaning system, the storage hopper ensures continuity of the process cycle and minimises the need for manual loading of abrasive media during operation of the complex.

The KASO-5 shot blasting complex is equipped with a filtration and extraction unit with an airflow capacity of 12,000 m³/h. The system continuously extracts dust-laden air from the working area, maintains visibility inside the chamber and helps provide suitable working conditions for the operator during shot blasting.

During operation, dust-laden air is drawn through the duct system to the filtration unit, where it is filtered through cartridge filters. Dust particles and products of abrasive breakdown are retained by the filter elements, while the cleaned air is discharged according to the selected operating mode of the system.

The unit is equipped with an automatic filter regeneration system that maintains stable air-cleaning efficiency and reduces the need for frequent servicing. Control of the extraction system is integrated into the overall control system of the complex.

Operation of the shot blasting complex is controlled by means of a centralised control panel that provides monitoring of the main process units. The system combines control of the filtration and extraction unit, abrasive regeneration system, chamber lighting and transport mechanisms, allowing the operator to supervise the equipment from a single control centre.

The panel displays information on the status of the equipment, enabling the operator to monitor system operation in real time and to respond promptly to changes in operating conditions or equipment faults.

For safe operation, safety interlocks and protective functions are provided, including monitoring of the filtration and extraction unit, bucket elevator and abrasive regeneration system, as well as an interlock that prevents the equipment from starting when the chamber gates or service door are open.