White Paper: Revolutionizing Anchor Chain Cleaning with a One-of-a-Kind Slat Blaster

Introduction

Anchor chains are critical components in maritime operations, requiring regular maintenance to ensure their reliability and longevity. Traditional methods of cleaning these heavy, massive chains often involve labor-intensive processes, manual handling, and significant time investment. In this paper, we introduce a revolutionary slat blaster designed to clean 20,000 anchor chains with unparalleled efficiency, transforming a previously time-consuming task into a highly automated, quick, and effective process.

Background

Historically, the cleaning of anchor chains has been a manual and time-consuming process. Operators would manually handle the chains, feeding them into traditional older designed blasting machines, which often took up to an hour to complete the cleaning cycle for a single chain. 30min blast with manual rotation and another 30min blast. This method not only exposed workers to potential safety hazards but also resulted in inconsistent cleaning quality and significant downtime.

Challenges of Traditional Methods

• Manual Handling: The heavy and cumbersome nature of anchor chains makes manual handling both challenging and dangerous. The risk of injury and fatigue is high, particularly when dealing with chains of significant length and weight.
• Time-Consuming: Traditional blasting methods, requiring around one hour per chain, lead to operational bottlenecks, reducing overall efficiency and increasing labor costs. As well as the increased operational costs for such an extension blasting time with media consumption and wear and tear on parts. Not to forget the cost of energy to run extended times.
• Inconsistent Cleaning: Manual processes often result in inconsistent cleaning quality, with some areas of the chain receiving inadequate attention, leading to potential operational failures.

The Innovative Slat Blaster: A Game-Changer

To address these challenges, we have developed a one-of-a-kind slat blaster that automates the cleaning of anchor chains, reducing the process time from one hour to just eight minutes. This innovative solution not only enhances safety and efficiency but also ensures consistent, high-quality cleaning.

Key Features

• Full Automation: The slat blaster is designed with automation at its core. Chains are fed into the machine without the need for manual intervention, significantly reducing the risk of injury and labor costs. Featuring full rotation of the part and consistency in cleaning.
• Rapid Cleaning Cycle: The system completes the cleaning process in just eight minutes, an 87% reduction in time compared to traditional methods. This rapid cycle enhances operational efficiency, allowing for more chains to be cleaned in a shorter timeframe.
• Uniform Cleaning: Equipped with advanced blasting technology, the slat blaster ensures a uniform and thorough cleaning of the entire chain, removing rust, scale, and other contaminants effectively.
• Durability and Reliability: Built to withstand the rigors of continuous operation, the slat blaster is engineered with durable materials and components, ensuring long-term reliability and minimal maintenance requirements.

Technological Innovations

• Custom Slat Conveyor System: The slat blaster features a custom-designed conveyor system that securely moves the anchor chain during the cleaning process to allow for full 360-degree coverage. This system is adaptable to different chain sizes and configurations, providing versatility in its application.
• High-Precision Wheels: The machine is equipped with high-precision wheels that deliver consistent blasting media coverage, ensuring that every link of the chain is cleaned to the highest standard.
• Smart Control System: An integrated smart control system allows operators to monitor and adjust the cleaning process in real time, optimizing performance and energy use.

Operational Impact

The introduction of the slat blaster into the anchor chain cleaning process has resulted in significant operational improvements:

• Increased Throughput: The ability to clean chains in just eight minutes allows for a dramatic increase in throughput, enabling maritime operations to maintain more equipment in less time.
• Reduced Labor Costs: Automation reduces the need for manual labor, cutting down on associated costs and minimizing the risk of injury.
• Enhanced Safety: By eliminating the need for manual handling, the slat blaster significantly improves workplace safety, reducing the risk of accidents.
• Consistent Quality: The machine’s precision and consistency in cleaning ensure that all chains meet strict operational standards, reducing the likelihood of failure due to inadequate maintenance.

Case Study

A leading maritime operator recently integrated the slat blaster into their anchor chain maintenance operations. Prior to the implementation, the cleaning of a 20,000-anchor chain took approximately one hour and required twostep process with dangerous handling. After deploying the slat blaster, the process was reduced to eight minutes, with no manual handling required. This resulted in a 650% increase in productivity and a 30% reduction in labor costs. Additionally, the quality of the cleaned chains improved significantly, leading to fewer operational issues and extended chain life.

Conclusion

The development and deployment of this innovative slat blaster have transformed the anchor chain cleaning process, setting a new standard for efficiency, safety, and quality in the maritime industry. By reducing cleaning time from one hour to just eight minutes and eliminating the need for manual handling, this technology not only enhances operational productivity but also ensures that anchor chains are maintained to the highest possible standards. As the maritime industry continues to evolve, the adoption of such advanced automation technologies will be critical in maintaining competitiveness and operational excellence.

Future Outlook

As we continue to refine and expand the capabilities of the slat blaster, future developments may include the integration of paint process following. The success of this initial deployment suggests a promising future for the widespread adoption of this technology across various maritime operations worldwide. As well as Foundry's across the globe looking to improve their cleaning process.

This white paper presents the slat blaster as a breakthrough in anchor chain maintenance, offering a compelling case for its adoption in any operation seeking to improve efficiency, safety, and maintenance quality.

Let's drive deeper into the ROI

Return on Investment (ROI) Analysis: Transition from 1-Hour to 8-Minute Cycle Time

The transition from a manual, 1-hour cycle to an automated 8-minute cycle for cleaning anchor chains using the new slat blaster has profound implications for return on investment (ROI). Here’s an in-depth analysis of the key factors contributing to the ROI:

1. Increased Throughput and Productivity

Before Automation:

• Cycle Time: 1 hour per chain.
• Output: With a single shift (e.g., 8 hours), only 8 chains could be cleaned.
• Labor Involvement: Manual handling required, typically involving multiple workers or unsafe work environment.

After Automation:

• Cycle Time: 8 minutes per chain.
• Output: The same 8-hour shift now allows for up to 60 chains to be cleaned.
• Labor Involvement: Minimal manual handling, significantly reducing the need for operator intervention and increasing safety.

Impact on ROI:

• Productivity Increase: The new system increases productivity by approximately 650%. This allows the operation to handle significantly more volume without increasing labor costs.
• Revenue Growth: With higher throughput, the ability to take on more projects or expedite existing ones can lead to increased revenue streams. If each cleaned chain represents a specific value, multiplying this value by the increased number of chains cleaned provides a direct boost to revenue.

2. Labor Cost Savings

Before Automation:

• Labor Requirements: Typically, two or more operators are needed for manual handling, supervision, and operation of the blast process.
• Hourly Wages: Assuming an average hourly wage per operator, labor costs are substantial.

After Automation:

• Labor Requirements: The automated system requires minimal supervision, reducing the number of operators needed per shift.
• Labor Cost Reduction: The reduction in labor requirements directly translates to cost savings. For example, if the operation previously required two operators for 8 hours, automating could reduce this to one operator or even allow that labor to be reallocated to other tasks, enhancing overall productivity.

Impact on ROI:

• Cost Savings: The reduction in direct labor costs and the potential for labor reallocation result in significant cost savings over time. This reduction in ongoing expenses contributes directly to an improved ROI.

3. Reduced Operational Downtime

Before Automation:

• Manual Process Variability: Manual handling introduces variability in process times, leading to potential delays and inefficiencies.
• Maintenance Interruptions: Traditional methods may require more frequent maintenance, resulting in operational downtime.

After Automation:

• Consistent and Predictable Process: The automated slat blaster provides a consistent and predictable cleaning time of 8 minutes, reducing variability.
• Less Downtime: The robust design of the slat blaster reduces the frequency of maintenance interruptions, ensuring a higher uptime and consistent operation.

Impact on ROI:

• Increased Uptime: Higher operational uptime means more chains can be cleaned in the same period, further enhancing throughput and revenue potential.
• Cost Efficiency: Reduced maintenance and fewer process interruptions translate to lower operational costs and higher overall efficiency.

4. Improved Quality and Reduced Rework

Before Automation:

• Inconsistent Cleaning Quality: Manual processes often lead to inconsistent cleaning results, necessitating rework or leading to premature wear or failure of inadequately cleaned chains.
• Rework Costs: Reworking defective chains incurs additional costs in terms of labor, materials, and time.

After Automation:

• Uniform Quality: The slat blaster’s precision ensures uniform cleaning, reducing the likelihood of defects and the need for rework.
• Extended Chain Life: Consistent and thorough cleaning can extend the life of anchor chains, reducing the frequency of replacements.

Impact on ROI:

• Cost Reduction: Fewer instances of rework and extended chain life contribute to lower material costs and reduced capital expenditures over time.
• Revenue Preservation: Consistent quality helps maintain the reliability of maritime operations, avoiding costly downtime due to chain failures.

5. Safety Improvements and Risk Reduction

Before Automation:

• Safety Risks: Manual handling of heavy anchor chains presents significant safety risks, potentially leading to workplace injuries.
• Associated Costs: Injuries lead to direct costs (medical expenses) and indirect costs (lost productivity, insurance premiums).

After Automation:

• Enhanced Safety: The automated process minimizes manual handling, significantly reducing the risk of workplace injuries.
• Lower Insurance Costs: Fewer workplace injuries can lead to lower workers’ compensation insurance premiums and related costs.

Impact on ROI:

• Cost Avoidance: By reducing the frequency of workplace injuries, the operation can avoid significant costs associated with accidents, further improving ROI.

6. Initial Investment and Payback Period

Initial Investment:

• Capital Costs: The upfront cost of the slat blaster is an important consideration. However, this should be viewed in the context of the substantial gains in efficiency, productivity, and cost savings.

Payback Period:

• Quick Payback: Given the significant reductions in cycle time, labor costs, and operational downtime, the payback period for the slat blaster can be relatively short. Depending on the specific financials, ROI can be achieved within a few months to a year.

Impact on ROI:

• Long-Term Gains: After the payback period, the operation will continue to benefit from the ongoing cost savings and productivity improvements, leading to a substantial cumulative ROI over the life of the equipment.

Conclusion

The transition from a 1-hour to an 8-minute cycle time with the automated slat blaster offers significant ROI through increased throughput, labor cost savings, reduced downtime, improved quality, and enhanced safety. These factors, combined with a relatively quick payback period, make the investment in this technology a compelling choice for any operation seeking to optimize anchor chain cleaning processes.

Need help with your cleaning of a special needs' product. LS Ind can help.

Melissa Gibson - head of Sales