Wuhan Hongxin Lixin Metal Products Co., Ltd. (Mali Steel Shot) recently completed an abrasive optimization project for a precision foundry in Hubei. The plant produces automotive castings at roughly 800 tons per month, runs three hook-type blast machines, and had been using a competitor's S330 cast steel shot.

After three months of operation, shot consumption dropped from 15kg to 10kg per ton of castings, and annual abrasive spend fell from about 720,000 RMB to 480,000 RMB.

The three problems

First, high consumption: 15kg per ton of castings, about 12 tons a month, roughly 720,000 RMB a year.

Second, excessive fractured shot and dust. Dust collector filters had to be replaced almost monthly, and workers complained about the shop environment.

Third, incomplete cleaning. Sand remained in recesses, and the rework rate sat around 8%.

The three-step fix

1. Changed the abrasive grade. The single S330 (0.8-1.0mm) was too light for heavy-wall castings. We switched to a graded S330:S460 = 6:4 mix — S460 (1.0-1.4mm) strips heavy scale, S330 finishes the surface.

2. Adjusted blast wheel current. Current had been set at 22A, too low for adequate shot velocity. We raised it to 28A based on casting wall thickness, increasing impact energy by 40%.

3. Calibrated the separator. Airflow had been too high, carrying away about 15% of good shot. After calibration, the share of silver (unbroken) shot at the discharge rose from 75% to 93%.

Results after three months

• Shot consumption: 15kg/ton → 10kg/ton
• Monthly usage: 12 tons → 8 tons
• Annual abrasive cost: ~720,000 RMB → ~480,000 RMB
• Rework rate: 8% → 2%

In the customer's words: "We used to think cheaper shot was better. After switching to Hongxin Lixin we learned that cutting consumption beats everything."

Common questions

Q: What abrasive should a foundry use for blast cleaning?

A: S330 and S460 steel shot for general castings; add steel grit for deep pockets; S230/S280 for thin-wall castings.

Q: What is a normal consumption rate?

A: 8-12kg per ton of castings. Above 15kg, check fracture rate and separator calibration.

Q: Why does changing the abrasive grade cut consumption?

A: A single size leaves gaps uncovered, so operators blast repeatedly. A graded mix covers the surface in one pass.

Wuhan Hongxin Lixin Metal Products Co., Ltd. (Mali Steel Shot) — Specialized & Innovative "Little Giant" enterprise and National High-Tech Enterprise (GR202342009917). Cast steel shot, steel grit, cut wire shot, conditioning shot, and graded abrasives. Free on-site testing for foundry customers. www.ieqq.cn | +86-400-038-8928