Because of the major environmental benefits of recycling and the inherent cost advantage to the end user, the global market for quality remanufactured automotive parts and assemblies is vast and is still growing. New international legislation such as the soon-to-be-implemented European ‘End of Life Vehicle’ Directive, which requires virtually all of the materials and parts that make up a vehicle to be recycled or refurbished, are also adding to the importance of the remanufacturing sector.
Delco Remy is the world’s largest remanufacturer of starter motors and alternators, covering vehicles of all types - from passenger cars to agricultural and industrial plant - and operates a number of remanufacturing plants in Europe, including a ‘quick response’ facility near Lichfield, UK, (a site formerly operated by Lucas Aftermarket, which was acquired by Delco Remy in 1998).
The facility stocks a huge number of refurbished starters and alternators, mainly for cars, small vans and light commercial vehicles, and provides a ‘next-day’ service, with the ability to produce a finished item to order within four hours.
In order to maintain high stock levels, the degreasing, cleaning and refurbishment of previously used electrical assemblies is virtually continuous. To ensure thorough cleaning, the smaller rotating components - cams and gear races, for example - require particular attention. These can be in a range of materials, from different types of plastics to brass, copper and steel, and often include recessed areas or blind holes that can pose difficulties for some automated cleaning methods.
To ensure efficient processing of these smaller parts, Delco Remy has installed a ‘Vapormaster 1212’ wet abrasive blasting machine, manufactured by Vapormatt, which degreases and cleans the parts in a single, automated, operation, on a batch basis. A major advantage of the machine is its ability to process mixed batches of plastics and metal parts, without creating any surface damage. Its installation supersedes the use of separate washing and dry-blasting operations and has considerably streamlined the cleaning and degreasing procedure.
The parts are processed in a tumble barrel, with an aqueous degreasing solution and stainless steel media applied by four specially positioned processing nozzles. Media dosing is automatic. A typical cleaning and degreasing cycle lasts 20 minutes and includes clean hot water rinsing and hot air drying using six further, separate processing nozzles - two for rinsing and four for drying. Batch sizes vary according to production needs.
The whole operation is self-contained, with the machine working on a closed-loop basis; process water is continuously filtered and waste material and debris is directed to a container for regular removal by a trade waste collection service.
Other features of the Vapormaster 1212 include: an advanced pump/sump design which prevents blockages, even after prolonged shutdown; the use of long-life urethane components in areas subject to particular wear; low air consumption processing guns (1.2m3/min at 5.5bar/40cfm at 80psi); and a rigid steel chassis with inset non-corrosive grp panels to reduce noise. The machine has been designed to minimise maintenance and includes an ‘hours run’ meter indicating necessary service intervals. The Vapormaster 1212 has a 1150mm x 1100mm x 985mm processing enclosure.
