The manufacturing industry is under immense pressure now so every penny counts, and that’s why it’s understandable that when it comes to abrasives, it’s easy to scrutinise the unit cost, to make immediate savings. But 50 years of experience tells us that not all abrasives are created equal, and with the latest developments in minerals and technologies, they’re even less so.
At HAYLEY DEXIS, we partner directly with suppliers to solve customer problems, and we know that a deep understanding of innovations helps us deliver efficiencies. 3M is a global leader in science and innovation, leading in industries like materials science, worker safety (PPE), industrial adhesives and abrasives, and they sat down with us to discuss the latest and greatest in its research and development of abrasives, and how it’s supporting the industry’s efficiency and safety with a 60% faster cut rate.
Why Saving A Few Pounds Can Cost More
Abrasives are used on many factory shopfloors to modify the surface of a workpiece, ranging from significant stock removal in the case of weld preparation or minor stock removal for light deburring or polishing but in all cases the abrasive will remove material to achieve its function. To remove material the abrasive, has a significant element, which contains the minerals (the rough bits). In the manufacture of an abrasive the minerals are a big contributor to the cost.
To save money, smaller quantities of mineral or a cheaper type can be used, but there is a cost to this price reduction, as it will impact the abrasive performance and take longer to do the job. So, by saving a few pounds on the purchase price of an abrasive, a job might take an extra time of an operator’s labour, this will impact shopfloor productivity increasing the price and could increase exposure to many long-term hazards, for example hand-arm vibration, noise and airborne particles.
It’s often said that if you spend a bit more, you save a lot more in time and efficiency, but in 3M’s case, it’s evidenced, as they regularly test their products in comparison to the best currently on the market and often commission independent third party testing to assess their products. They are committed to continuous product research and development to better support industry and want to prove that using the best is the right choice for productivity and safety.
Shape Matters In Minerals
An example of the research and development into mineral technology is the introduction of 3M’s re-engineered Precision-Shaped Grain, which boosts the speed and life of 3M™ Cubitron™ Performance Abrasives. Having previously discovered in the early 2000’s that a triangular shape of mineral (grain) reduces cutting time, 3M has pushed this further to curve in, the sides of the triangular grain to push the cut rate even further. This has the effect of making the tip of the grain sharper, increasing its efficiency whilst also reducing the bearing area by keeping the tip sharper for longer as it self-sharpens during its use.
This advancement prioritises operator safety, reducing job times and exposure to hazards, maximises sustainability, by cutting more and wearing less, it increases the lifetime of the abrasive, and amplifies productivity and efficiency.
"HAYLEY DEXIS and 3M collaborate well to provide a formidable offer when delivering value for end users." – Daniel Guest, Channel Manager, 3M
Health & Safety
The innovation also has broader benefits for employees, particularly in health and safety, while helping employers comply with regulations. There are four key areas that abrasives impact:
Hand-arm vibration, airborne particles, noise, and cuts and other injuries.
Within each of these areas are guidelines and laws that employers use to assess risk and compliance. Following best practice, it’s recommended that employers eliminate or reduce risks in the first instance by following the hierarchy of control with the most effective, elimination, substitution, engineering controls, administrative controls, and PPE which is the least effective. HAYLEY DEXIS, as a strategic partner, works with 3M and our clients to investigate and, where possible, replace traditional abrasives prone to high levels of vibration, noise, and airborne particles with 3M™ Cubitron™ 3 Performance Abrasives to help reduce these hazards.
3M’s gold-standard respiratory solutions, such as the Speedglas welding helmet further help protect operators from airborne particulate matter when cutting, grinding and welding.
Our partnership with 3M means that together we can advise on changes in work procedures to reduce the duration, frequency, and severity of exposure to abrasive-related hazards. PPE is the last line of defence against abrasive hazards but remains an important component to consider for the residual risks regardless of what other controls are in place, and that’s also a solution 3M provides.
Abrasives are such a small product in a line of many orders a manufacturer will place; however, when there’s an opportunity to increase productivity by 60%, it makes sense to think about quality. As we work to make the industry safer, we are also another step closer to creating a better environment for hardworking operators.
Sources: 3M Cubitron 3 Fibre Discs 1182C 1187C Brochure EMEA