Brass instrument surface finishing
For musical instruments companies
The client is a manufacturer of mouthpieces and brass instruments based in Europe. They specialize in high-value mouthpieces made of brass and gold or silver-plated. The organization is always seeking technologies to improve the quality of their products and overcome challenges in providing perfect mouthpieces, free of defects.
THE PROBLEM
Before adopting GPAINNOVA’s solution, the customer used to carry out manual polishing with brushes, felts, and polishing compounds in a manual workstation. Besides being significantly resource-demanding, these procedures were not cost-efficient and led to a high rate of defective parts, resulting in a lack of quality in the final product.
Manual polishing, as an abrasive method using brushes, felts, and polishing pastes, resulted in inconsistent finishes between batches and a high risk of deformation of the pieces, leading to alterations in geometry and size. Additionally, it incurred high labor costs and required a significant amount of time for polishing.
THE GOAL
The company was seeking to enhance the production productivity and quality of their brass instruments. The customer needed to polish the pieces to achieve higher quality and a longer lifespan. The polishing target was to achieve a mirror surface finishing. As some of the mouthpieces were laser engraved, the surface finishing process needed to preserve the original design without any alterations.
THE SOLUTION
Considering a weight removal of 0.1 grams per piece and the weight removal capacity of a DLyte PRO500’s full media work bowl of 210 liters —in the case of brass with dry suspension media, it is 4.04 kg—, GPAINNOVA, thanks to its DLyte solutions, can treat 40,400 parts per media lifecycle. Based on the processing time of 10 minutes and an estimated total time for loading and unloading the holders of 4 minutes, the total process time is 14 minutes per batch of 40 pieces. The daily output, considering 1 shift, is 1,500 inserts, and the annual output, assuming 250 working days, is 400,000 units.
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