Cost-Benefit Analysis of Shot Blasting Machines in Surface Treatment
Author – Kishan Vishwakarma
Kishan Vishwakarma
COPYRIGHT @ 2025
Cost-Benefit Analysis of Shot Blasting Machines in Surface Treatment
Author – Kishan Vishwakarma
Abstract:
This paper explores the cost-effectiveness of shot blasting machines in industrial surface treatment, emphasizing their importance in surface cleaning and preparation. Shot blasting is integral to enhancing surface quality, ensuring better adhesion, durability, and coating results. The study evaluates both the initial investment and the ongoing operational costs associated with shot blasting machines, weighing them against the benefits they deliver, such as increased production efficiency, reduced labor costs, and improved surface quality.
By analysing case studies and examples across various industries, the paper provides practical insights into the financial viability of investing in shot blasting equipment. The goal of this research is to assist manufacturers and industry professionals in making informed decisions regarding their surface treatment methods, ultimately improving both performance and long-term cost efficiency.
Additionally, the paper offers guidance on optimizing surface preparation processes, fostering higher operational productivity and enhanced product quality. The findings of this analysis serve as a resource for industries aiming to maximize their return on investment in shot blasting technology, ensuring cost-effective and efficient surface treatment solutions.
Introduction:
Shot blasting is a crucial process in surface preparation used across various industries to clean and treat surfaces, improving their quality and performance. By blasting abrasive materials, such as steel shots or grit, against a surface, shot blasting removes contaminants like rust, scale, and dirt. This results in a cleaner, rougher surface that enhances the adhesion of coatings and increases the overall durability of the material. Whether applied in the automotive, steel, or construction industries, shot blasting ensures that materials are ready for further treatments, like painting or coating, thereby improving their longevity and structural integrity.
While shot blasting provides numerous benefits, one significant consideration for manufacturers is the cost associated with these machines. The upfront investment required to purchase shot blasting equipment can be high, and the ongoing costs of maintenance, energy, and consumables must also be factored into the equation. This paper aims to analyze the economic viability of shot blasting machines by evaluating the costs versus the benefits they offer. Specifically, it looks at how these machines can improve production efficiency, reduce labor costs, and deliver better surface quality compared to traditional methods, like manual cleaning or sandblasting.
Through case studies from various industries, this paper seeks to provide valuable insights that can guide manufacturers in deciding whether the investment in shot blasting technology is worthwhile. By highlighting the operational advantages, such as increased productivity, lower labor costs, and enhanced surface results, the paper aims to demonstrate how shot blasting machines can lead to long-term cost savings. Additionally, it will explore strategies for optimizing their use, helping manufacturers improve their surface treatment processes while keeping operational costs in check.
This research aims to provide industry professionals with a clear understanding of the financial implications of adopting shot blasting machines. By analysing both the costs and the benefits, the goal is to offer guidance on making smarter investments in surface treatment technology, ultimately improving productivity and product quality.
The use of shot blasting machines in industrial surface treatment has been extensively studied for its efficiency in cleaning and preparing surfaces. According to Smith and Johnson (2018), shot blasting significantly improves surface adhesion and coating durability, making it a preferred method in industries such as automotive, construction, and aerospace.
Their research highlights the role of shot blasting in enhancing product longevity and reducing maintenance costs.
1. Testing Shot Blasting Machines in Industrial Conditions
R. Wrona and P. Zyzak (2012)
• Investigated the performance of shot blasting machines in real industrial environments.
• Emphasized the importance of machine durability and reliability under continuous operation.
• Provided insights into the challenges faced during the integration of shot blasting machines in production lines.
2. Review on Shot Blasting Processes
Deepanshu Prasad (2018)
• Conducted a comprehensive review of various shot blasting techniques and their applications.
• Discussed the advantages and limitations of different abrasive materials used in shot blasting.
• Highlighted the evolution of shot blasting processes and their impact on industrial efficiency.
3. Factors Affecting Shot Blasting Performance
Arjun Kadam (2023)
• Identified key factors influencing the effectiveness of shot blasting, such as abrasive type, machine settings, and surface condition.
• Analyzed the relationship between shot blasting parameters and the quality of surface finish with help of equipment’s
• Suggested best practices for optimizing shot blasting performance in different industrial scenarios such as; aerospace, railway, and automotive.
4. Research on Optimization Design of Shot Blasting Machine
Yinhang Zhang et al. (2021)
• Explored the optimization of shot blasting machine design to enhance operational efficiency.
• Focused on reducing energy consumption and improving the precision of abrasive such as; steel shots & steel grit delivery.
• Presented innovative design solutions to address common issues in traditional shot blasting machines.
5. Characteristics of The Outer Surface Layer in Casts Subjected to Shot Blasting Treatment
A. Fedoryszyn and P. Zyzak (2010)
• Examined the effects of shot blasting on the outer surface layer of cast materials.
• Found that shot blasting significantly improves surface hardness and resistance to wear.
• Provided detailed analysis of microstructural changes in the treated surface, contributing to improved mechanical properties.
6. Future Trends in Shot Blasting Machine Design
Kishan Vishwakarma (2024)
• Discussed emerging trends in the design of shot blasting machines, focusing on automation and smart technology integration.
• Highlighted advancements in eco-friendly designs, emphasizing reduced energy consumption and waste generation.
• Predicted the growing use of AI and machine learning to optimize shot blasting processes and enhance performance monitoring.
7. Shot Blasting Machine Working Principle and Benefits
Ambica and Jai Singh (2023)
• Explained the fundamental working principles of shot blasting machines, including the mechanics of abrasive propulsion and surface impact.
• Outlined the primary benefits of shot blasting, such as improved surface cleanliness, enhanced coating adhesion, and increased product lifespan.
• Provided practical insights into how shot blasting contributes to overall industrial productivity and cost savings.
Methodology:
This research employs a mixed-methods approach, combining quantitative and qualitative analysis to evaluate the cost-benefit aspects of shot blasting machines in industrial surface treatment. The study involves the following key steps:
1. Data Collection
Primary data is collected through direct observation and performance analysis of shot blasting machines in various industrial settings. Secondary data is gathered from industry reports, academic journals, and manufacturer documentation to provide a comprehensive understanding of the costs and benefits associated with shot blasting.
2. Case Studies
Detailed case studies of selected industries are conducted to illustrate the practical application of shot blasting machines. These case studies focus on sectors such as automotive, construction, and aerospace, where surface treatment is critical. Each case study includes an analysis of machine performance, cost implications, and the resulting improvements in surface quality.
3. Cost Analysis
The cost analysis examines both capital and operational expenses related to shot blasting machines. This includes the initial purchase cost, maintenance, energy consumption, and labor costs. The analysis also considers potential cost savings from reduced labor requirements, increased efficiency, and extended product life due to superior surface preparation.
4. Benefit Assessment
The benefits of shot blasting are evaluated based on improvements in surface quality, production efficiency, and environmental impact. Metrics such as surface roughness, coating adhesion, and defect rates are used to quantify quality improvements. Productivity gains are measured through production cycle times and output rates.
5. Comparative Analysis
A comparative analysis is conducted to benchmark the performance and cost-effectiveness of shot blasting machines against alternative surface treatment methods, such as sandblasting and chemical cleaning. This analysis helps to highlight the relative advantages and potential trade-offs of using shot blasting technology.
6. Data Synthesis and Reporting
The collected data is synthesized to draw meaningful conclusions about the cost-benefit dynamics of shot blasting machines. The findings are presented in a structured format, highlighting key insights, recommendations, and potential areas for further research.
Introduction to Shot Blasting Machines:
Shot blasting machines are essential in industrial surface treatment, used to clean, prepare, or strengthen materials. By propelling abrasive media at high speeds, they enhance surface quality, remove contaminants, and improve durability.
Understanding their cost-effectiveness is crucial for making informed investment decisions.
1. What Are Shot Blasting Machines?
Shot blasting machines are mechanical devices designed to clean, polish, or strengthen metal and other hard materials by propelling abrasive media, such as steel shot, grit, or sand, at high speeds. These machines are commonly used in various industries, including automotive, aerospace, construction, and manufacturing, for applications like rust removal, surface preparation, and stress relief.
2. The Importance of Surface Treatment
Surface treatment is a critical process in industries that deal with metals and hard materials. Proper surface treatment not only improves the aesthetic appearance of the materials but also enhances their performance, longevity, and resistance to wear and corrosion. Shot blasting, as part of this treatment, plays a significant role by preparing surfaces for subsequent processes like painting, coating, and welding.
3. How Shot Blasting Machines Work
The basic principle of shot blasting involves using high-pressure air or mechanical means to accelerate abrasive particles, called "shots," and direct them at a surface. This action removes contaminants, scales, and rust while simultaneously improving the surface profile for better adhesion of coatings or other materials.
4. Different Types of Shot Blasting Machines
Shot blasting machines come in various types, including:
1. Tumble Blasters: Ideal for small parts or batch processing, where materials are rotated within a drum while being blasted.
2. Spinner Hangers: Suspended parts are rotated in a chamber to expose all surfaces to the abrasive shot.
3. Continuous Blast Machines: These are used for larger parts that move continuously through a blasting zone.
4. Table Blasters: For precise blasting of smaller components with an automated system to rotate and expose surfaces.
Data Collection from Indian Shot Blasting Machine Manufacturers:
For the purpose of this research on the cost-benefit analysis of shot blasting machines in surface treatment, data was collected from both primary and secondary sources. The data was focused on operational costs, productivity gains, and the quality of surface treatment when using shot blasting machines. The collection process involved:
Primary Data: Interviews were conducted with 15 manufacturers of shot blasting machines, 10 facility managers, and 20 operators in industries utilizing shot blasting machines for surface treatment. The goal was to gather firsthand information on the cost of machines, energy consumption, maintenance schedules, and production rates.
Secondary Data: A review of existing literature, including industry reports, academic papers, and market research studies, was performed to compare and contrast the results from primary data. Notable sources included industry journals such as "Surface Treatment & Coatings," reports from the International Surface Finishing Association (ISFA), and market reports from equipment suppliers.
As part of the research on the "Cost-Benefit Analysis of Shot Blasting Machines in Surface Treatment," data was gathered from 15 prominent Indian shot blasting machine manufacturers. The aim was to collect insights on machine specifications, cost structures, maintenance practices, and operational efficiency, which would aid in evaluating the financial and operational impact of integrating shot blasting machines in industrial surface treatment.
Overview of Manufacturers
The surveyed manufacturers such as (Airo shot blast, Ambica Enterprises, Shot Blaster, Micro Blaster, and Spray Blast India), including well-established brands and emerging companies, represent a diverse cross-section of the Indian manufacturing industry. Each manufacturer was evaluated based on the following parameters:
Machine Price Range: Prices varied depending on machine specifications, size, and features. The typical price range for medium to large shot blasting machines is between ₹10,00,000 to ₹25,00,000, with high-end models reaching ₹30,00,000.
Operational Efficiency: Manufacturers emphasized that shot blasting machines significantly reduce production time, with efficiency improvements ranging from 15% to 30% depending on the machine type.
Energy Consumption: The energy consumption of machines varied, with most machines consuming between 4,000 kWh and 8,000 kWh annually. However, newer models and energy-efficient variants showed up to 20% reduction in energy usage compared to older designs.
Maintenance Costs: Maintenance costs are influenced by the machine model and usage. On average, manufacturers indicated that maintenance expenses range from ₹1,00,000 to
₹2,50,000 annually. Regular maintenance ensures better machine lifespan and higher operational efficiency.
Product Lifespan: Manufacturers indicated that with proper maintenance, shot blasting machines typically have a lifespan of 8 to 10 years, with some models being used for over 15 years under optimal conditions.
Technological Advancements: Several manufacturers have integrated automation and advanced control systems, making the machines easier to operate and more efficient in terms of energy consumption and material handling. These advancements result in higher accuracy in surface treatment and reduced labor costs.
Insights from Manufacturer Data
➢ Cost Analysis: The average initial investment for a mid-range shot blasting machine was found to be around ₹12,00,000 to ₹18,00,000. However, manufacturers emphasized the long-term savings in labor, energy, and operational costs. The return on investment (ROI) for companies investing in shot blasting machines typically ranges from 200% to 450%, depending on the scale of operations and usage intensity.
➢ Labor Cost Reduction: Data revealed that automation in shot blasting machines could reduce labor costs by up to 60%. This reduction in labor demand is especially important in industries where labor costs are high and automation can lead to more consistent output quality.
➢ Surface Quality Improvements: Manufacturers highlighted that shot blasting machines lead to superior surface quality with a rating improvement of 30% to 40% compared to manual cleaning methods. This enhanced quality directly impacts product lifespan and customer satisfaction, leading to better market prices for treated products.
➢ Energy Efficiency: Energy-efficient shot blasting machines, which incorporate advanced technologies like variable frequency drives (VFDs) and better air filtration systems, were reported to reduce energy consumption by up to 20%, contributing to both cost savings and environmental sustainability.
Reporting Results:
The data collected and synthesized provides a comprehensive view of the cost-benefit landscape for shot blasting machines in surface treatment. The following findings were observed:
1. Return on Investment (ROI): Companies that adopted shot blasting machines saw an average ROI of 30-40% per year. In large-scale operations, ROI was achieved within 2-3 years, while smaller facilities took up to 4 years to reach the break-even point.
A facility that invested INR 20,00,000 in shot blasting machines recouped the investment within 2 years due to increased production efficiency and reduced labor costs.
2. Productivity Gains: Production speed increased by 40-50% across most facilities. Some companies reported even greater improvements, with one large plant achieving a 70% increase in throughput after upgrading to shot blasting technology.
A plant producing automotive parts was able to reduce its surface treatment time per unit by 50%, allowing for faster turnaround and reduced lead times.
3. Cost Reduction: Operational costs were reduced by 20-30%, primarily due to lower labor costs and more energy-efficient operations. Maintenance costs remained steady, with facilities reporting minimal downtime and fewer maintenance requirements.
The annual energy costs for a plant using shot blasting machines were reduced from INR 4,00,000 to INR 3,00,000.
4. Quality Improvement: The quality of surface treatment improved by 15-25%. This was reflected in fewer defects, higher customer satisfaction, and lower costs associated with rework.
A steel fabrication company noted a 20% decrease in surface defects, leading to enhanced customer relationships and fewer returns.
5. Environmental Impact: Shot blasting machines were found to be more environmentally sustainable compared to traditional methods. Waste reduction and energy savings contributed to a greener operation, aligning with increasing industry focus on sustainability.
A manufacturer of construction equipment reduced its abrasive waste by 25%, lowering disposal costs and contributing to environmental goals.
Conclusion from Manufacturer Data
The information gathered from these 15 Indian manufacturers such as (Shot Blaster, Airo shot blast, Ambica Enterprises India, Micro Blaster, and Spray Blast) demonstrates that the integration of shot blasting machines significantly enhances the efficiency of surface treatment processes. The combination of lower labor and maintenance costs, improved surface quality, and energy efficiency makes shot blasting machines a highly cost-effective solution in industries such as automotive, steel, and construction.
The data also supports the notion that the return on investment (ROI) for these machines is substantial, with manufacturers reporting ROI ranging from 200% to 450% over a 5-year period. This collected data forms a crucial part of the research paper, contributing to the costbenefit analysis by providing real-world insights from industry leaders.
These findings will be used to compare theoretical data with practical outcomes and validate the financial benefits associated with the use of shot blasting machines in industrial surface treatment.
Figure 1: ROI Calculation for Shot Blasting Machines
Benefit Assessment of Shot Blasting Machines in Detail:
Enhanced Surface Finish and Cleanliness
One of the primary benefits of shot blasting is the improvement of surface finish. By using abrasive materials at high velocity, shot blasting machines remove unwanted contaminants such as rust, old paint, and debris from metal or other materials. This process results in a cleaner, smoother surface that is more suitable for subsequent treatments like coating or painting.
The enhanced surface finish ensures better adhesion of paints, coatings, or any other subsequent layers, reducing the chances of peeling or corrosion over time. This improves the aesthetic quality and durability of the treated components.
Stress Relieving and Durability
Shot blasting also plays an essential role in relieving stress on metal parts. During the blasting process, the surface of the material is subjected to compressive forces, which help to relieve internal stress and prevent the formation of cracks or fractures. This makes the components more resistant to fatigue and wear, ultimately extending their service life.
Additionally, shot blasting can improve the material’s mechanical properties. By inducing a compressive residual stress layer on the surface, the machine strengthens the parts, making them more durable under load and less prone to wear and tear.
Time and Labor Savings
Another key benefit of shot blasting machines is their ability to significantly reduce labor time. Traditional methods of cleaning or preparing surfaces often require manual labor, which can be slow and inefficient. Shot blasting machines automate this process, reducing the time spent per unit and increasing throughput. For manufacturers with high production volumes, this can result in substantial labor cost savings.
Moreover, the automated nature of shot blasting systems minimizes human error and ensures consistent results across large batches of components.
Eco-Friendly Operation
In today's industrial world, sustainability is an increasingly important concern. Shot blasting is considered an eco-friendly process compared to traditional methods of surface preparation. Since most of the abrasive media used in shot blasting machines can be reused multiple times, the process reduces waste and environmental impact.
Moreover, modern shot blasting systems are equipped with advanced filtration and dust collection systems that help minimize airborne contaminants. These systems improve air quality in the workplace and contribute to a healthier environment, complying with strict environmental standards.
Evaluating the Cost-Benefit Ratio of Shot Blasting Machines:
Reviewing the cost-benefit ratio of shot blasting machines means weighing the initial investment and ongoing costs against the long-term benefits. While they require a significant upfront cost, shot blasting machines boost efficiency, reduce labor, and improve surface quality, leading to savings over time.
These machines help lower rework, decrease manual labor, and enhance product durability, making them a worthwhile investment for manufacturers looking to improve productivity and profitability. A careful evaluation ensures that the benefits outweigh the costs in the long run.
Short-Term vs. Long-Term Impact
While the initial purchase of a shot blasting machine might seem costly, businesses often experience significant short-term and long-term benefits that make the investment worthwhile. Short-term advantages include immediate improvements in surface preparation, reduced labor costs, and enhanced efficiency. Long-term benefits manifest in the form of reduced maintenance costs, extended lifespan of treated components, and higher productivity.
These may include brand reputation for delivering high-quality products, the ability to handle larger workloads, and the competitive edge gained by implementing more efficient processes.
Return on Investment (ROI)
The ROI of shot blasting machines is often determined by analysing factors such as energy consumption, labor savings, reduced downtime, and the long-term durability of parts treated with shot blasting. Companies that operate in high-volume production environments or require stringent surface preparation will likely see a quicker ROI, as these machines streamline processes, improve surface quality, and prevent costly repairs or rework.
It's essential for companies to track key performance indicators (KPIs) such as processing speed, material usage efficiency, and reduction in scrap rates to determine the overall effectiveness of the shot blasting machine.
Cost-Benefit Analysis of Shot Blasting Machines (In INR)
Updated Cost Breakdown (In INR):
1. Without Shot Blasting:
• Labor: ₹56,25,000 (5 years)
• Maintenance: ₹18,75,000 (5 years)
• Operational Costs: ₹75,00,000 (5 years)
2. With Shot Blasting:
• Initial Investment: ₹12,00,000
• Labor: ₹17,50,000 (5 years)
• Maintenance: ₹6,25,000 (5 years)
• Operational Costs: ₹25,00,000 (5 years)
Benefit Breakdown:
• Increased Surface Quality: The shot blasting machine boosts surface quality, leading to better durability and customer satisfaction, which enhances product value.
• Reduced Labor & Operational Costs: Automation decreases labor requirements and production time, significantly lowering overall operational costs.
• Increased Revenue: The improved product quality and reduced production time result in increased revenue due to higher sales volume and customer retention.
Mode of Operation Analysis:
➢ Automatic Segment: Dominates due to the efficiency and speed of automated systems, which can process large volumes of workpieces consistently. This is a key driver for growth in several industries.
➢ Manual Segment: Although smaller, it offers flexibility, ease of installation, and maintenance, leading to moderate growth prospects.
Initial Investment
The cost of purchasing a shot blasting machine is often the first consideration for many businesses. The initial investment can be a significant expense, depending on the size, functionality, and complexity of the equipment. High-end machines designed for large-scale industrial operations can cost anywhere from tens of thousands to several hundred thousand dollars. While this upfront cost may appear daunting, businesses often recoup their investment over time as the benefits, such as increased efficiency and durability, outweigh the expenses.
Smaller, more specialized machines designed for specific tasks or smaller production scales may come at a lower cost but still provide valuable returns, especially when tailored to a company's unique needs.
Operational Costs
Once the machine is purchased, operational costs become the focus. Shot blasting machines, especially larger models, require a substantial amount of energy to operate efficiently.
Electricity is often the primary energy source, and depending on the frequency of use and the power requirements of the specific machine, this can become a significant recurring expense.
In addition to energy costs, abrasive media is an essential consumable in the shot blasting process. Whether it's steel shot, grit, or other types of abrasive materials, regular replenishment is necessary to maintain the machine's performance.
The cost of abrasives depends on the type of material being used and the machine’s efficiency in recycling the media.
Maintenance costs are another ongoing expense. Like any industrial equipment, shot blasting machines require regular servicing to ensure smooth operation. This includes replacing worn parts, cleaning the system, and inspecting components to prevent breakdowns.
Here are some of the sector wise costs -
• Automotive Sector: Expected to dominate the market due to high adoption rates of shot blasting machines for vehicle production and surface preparation needs.
• Aerospace Sector: Rapid growth is anticipated, driven by the demand for specialized cleaning and surface treatment of components made from materials like aluminium and titanium.
• Other Sectors: Including foundry, shipbuilding, construction, and rail, all showing growth due to increasing requirements for surface preparation and cleaning in manufacturing processes.
Comparative Analysis:
Choosing the Right Shot Blasting Machine for Your Needs
➢ Machine Size and Type: When selecting a shot blasting machine, it's crucial to consider the size of the components being treated and the type of treatment required. Different types of shot blasting machines, such as tumble blast, spinner hanger, or table blasters, are suited for different types of parts. Each type offers unique benefits, so understanding the production needs and expected throughput is key to making the right choice.
➢ Automation and Customization: Modern shot blasting machines often come with advanced automation capabilities, allowing for consistent and high-quality results with minimal human intervention. Customization options, such as adjustable blast pressure, media flow control, and specialized nozzles, allow the machine to be fine-tuned to specific tasks, ensuring optimal performance for various materials and surface treatments.
➢ Budget and Operational Considerations: The budget plays a crucial role in choosing the right shot blasting machine. While advanced automated machines offer high efficiency and precision, they may come with a higher price tag. Businesses should evaluate their specific needs, production volume, and available budget to find the best balance between cost and functionality
Conclusion:
Shot blasting machines offer significant cost benefits by enhancing productivity, lowering operational costs, and improving surface quality. These advantages, along with their reduced environmental impact, make shot blasting machines a worthwhile investment for industries involved in surface treatment. Their efficiency helps companies meet demanding production standards while maintaining cost-effectiveness, which is crucial in a competitive industrial landscape.
As technology advances, shot blasting machines are poised to become even more integral to industrial production and sustainability. The return on investment (ROI) is considerable, with most businesses reaching their break-even point within 2-3 years. This makes shot blasting machines a financially viable solution for companies looking to boost production capabilities while reducing overall operational costs.
By carefully evaluating the various cost factors and benefits, businesses can make informed decisions about adopting shot blasting technology. Whether used in small-scale operations or large industrial processes, these machines are crucial for achieving high-quality results and staying competitive in today’s fast-evolving market.
Annexures:
The annexures section provides supplementary information to support the research presented in this paper. These materials include additional data, charts, tables, and references that offer further insights into the study on the cost-benefit analysis of shot blasting machines in surface treatment. Below are the key annexures included:
Survey Questionnaire for Data Collection
A sample of the survey questionnaire used to collect primary data from manufacturers, facility managers, and operators involved in surface treatment. The questionnaire aimed to gather detailed insights into costs, productivity, quality improvements, and operational challenges associated with shot blasting machines.
Sample Survey Questions:
1. What is the size of your facility and the number of shot blasting machines in operation?
2. What was the initial capital investment required to purchase the shot blasting machines?
3. On average, what is your annual maintenance cost per machine?
4. How much energy (in kWh) does your shot blasting machine consume annually?
5. What is the percentage improvement in production speed since the introduction of shot blasting machines?
6. How would you rate the quality of surface treatment (uniformity, durability, and finish) before and after the use of shot blasting machines?
7. Has the use of shot blasting machines resulted in a reduction in defects or rework? Please provide examples.
8. What is the estimated payback period (ROI) for your shot blasting machine investment?
9. What steps have you taken to ensure environmental sustainability in the operation of your shot blasting machines?
Data Tables and Figures
This annexure includes the detailed tables and figures used for data analysis, including financial calculations, energy consumption data, and productivity improvements. These visuals help support the findings discussed in the paper.
Table 1: Breakdown of Initial Investment for Shot Blasting Machines
Table 2: Annual Operational Costs for Shot Blasting Machines
Figure 1: ROI Calculation for Shot Blasting Machines
(Visual representation of ROI over a 5-year period, highlighting cost recovery, operational savings, and profitability.)
Case Studies
Detailed case studies of facilities that implemented shot blasting machines, showing realworld examples of cost savings, productivity gains, and improvements in surface quality. These case studies offer context to the theoretical findings in the paper.
Case Study 1: Automotive Component Manufacturer – Airo Shot Blast Equipment
• Initial Investment: INR 20,00,000 for two medium-sized shot blasting machines.
• Annual Savings: Reduced labor costs by 25%, energy consumption decreased by 15%, and productivity increased by 40%.
• Outcome: The company achieved ROI within 2.5 years and reported a 20% decrease in surface defects.
Case Study 2: Steel Fabrication Facility – Shot Blaster
• Initial Investment: INR 30,00,000 for four large shot blasting machines.
• Annual Savings: Maintenance costs remained steady, while energy costs decreased by 10%. Productivity rose by 50%.
• Outcome: Break-even was achieved in 3 years, and surface treatment quality improved by 30%.
Literature Review References
A list of key sources referenced throughout the research paper, providing additional context and background for the study. This annexure includes books, journals, market research reports, and industry publications on surface treatment technologies and shot blasting machines.
Books:
1. "Surface Preparation and Coating Technologies" by John M. Walters.
2. "Industrial Surface Treatment" by Robert A. Smith.
Journal Articles:
1. "Energy Efficiency in Surface Treatment" - Journal of Surface Finishing, Vol. 15, 2021.
2. “Best Shot Blasting Machine Manufacturers in India” – Written by Kishan Vishwakarma
3. "The Role of Shot Blasting in Surface Coating Industries" - International Journal of Surface Engineering, Vol. 30, 2022.
Market Reports:
1. "Global Shot Blasting Machines Market Trends" – MarketsandMarkets, 2023.
2. "Indian Surface Treatment Industry Overview" – Frost & Sullivan, 2022.
Glossary of Terms
This annexure provides definitions for key terms used in the research, helping readers understand technical jargon related to shot blasting machines and surface treatment.
• Shot Blasting: A process used to clean, strengthen, or polish metal surfaces using high-velocity shots of abrasive materials.
• ROI (Return on Investment): A financial metric used to evaluate the profitability of an investment, calculated as the net gain divided by the initial cost.
• Throughput: The amount of material processed by the shot blasting machine within a given time frame.
Acknowledgments
The acknowledgments section recognizes the individuals and organizations that contributed to the research, including manufacturers, suppliers, facility managers, and academic advisors who provided invaluable insights and support.
References:
[1] R. Wrona and P. Zyzak (April 2012). Methodology of Testing Shot Blasting Machines in Industrial Conditions
https://www.researchgate.net/publication/271312704_Methodology_of_Testing_Shot_Blasting_Mach ines_in_Industrial_Conditions
[2] Deepanshu Prasad (2018). Review on Shot Blasting Processes
https://www.ijsrd.com/articles/IJSRDV6I20422.pdf
[3] Arjun Kadam (June 2023). Factors affecting shot blasting performance in foundries and suggested remedial measures
https://www.researchgate.net/publication/371377955_Factors_affecting_shot_blasting_performance_i n_foundries_and_suggested_remedial_measures
[4] Yinhang Zhang; Shuai Wang; Yongzhi Pan; Tianyi Zhang; Zhenfeng Jiang; Xiuli Fu (2021). Research on Optimization Design of Shot Blasting Machine Blade Based on Modal Analysis
https://ieeexplore.ieee.org/document/9612963
[5] A. Fedoryszyn, P. Zyzak (2010 Volume 55, issue 3). Characteristics of the Outer Surface Layer In Casts Subjected To Shot Blasting Treatment
https://www.imim.pl/files/archiwum/vol3_2010/23.pdf
[6] Nayan Sharma (2014). Portable Shot Blasting Machine Manufacturers in India
https://www.sandblast.in/product/Portable-shot-blasting-machines
[7] Ajay Singh Rathore (2010). Leading Shot Blasting Machine Manufacturer in India for Sale
https://www.airoshotblast.net/main-product/19-Shot-Blasting-Machine
[8] Amit Kumar & Ajit Sharma (2015). Hanger Type Shot Blasting Machine, Closed Loop, Door type Shot Blaster
https://www.sandblastingmachine.in/hanger-type-shot-blasting-machines
[9] Kishan Vishwakarma (2024) The Future of Shot Blasting in Industrial Applications
https://kishanvns55.medium.com/the-future-of-shot-blasting-in-industrial-applications-ambicaenterprises-e9ec25381fe7
[10] Ambica Singh and Jai Rathore (2024). Shot Blasting Machine Working Principle and Benefits
https://medium.com/@jp1092764/shot-blasting-machine-working-principle-a3c2e7c4d976