As a premier supplier of sustainable site solutions to huge UK sectors such as construction and utilities, Garic's operations rely on efficient production processes that can meet customer demand.
​The partnership between Garic and Hodge Clemco began in 2014 when they approached the business wanting to invest in their first blast pot package and JBlast abrasive.
​As this project, and Garic’s need for additional capacity, developed, SurfacePrep helped the Bury-based business establish a dedicated acoustic blastroom and then returned once again in 2024 to address increases in consumption and waste.
​Their latest investment introduced abrasive recovery and recycling equipment into their facility to meet new production requirements. In this latest case study, you can see how industrial blasting operations can develop in stages that respond to the needs of the business.
2014: The beginning of Garic's blasting journey
Back in 2014, Garic’s initial foray into blasting was rather straightforward. They needed a blast pot package and a JBlast abrasive to complete semi-regular blasting procedures inside an existing shed without a dedicated extraction or abrasive recovery system.
​This initial arrangement was ideal for Garic, as was the expendable abrasive designed for single use, JBlast.
​Garic now had an established blasting operation in place that did not require committing to the cost of a complete blast room and recovery system. As the operation developed in the months and years to come, though, the limitations of the original working environment created a reason for Garic to consider a more substantial investment.
2020: Investing in a dedicated acoustic blast room
Six years on from their initial blasting investment, Garic took a significant step forward by investing in their very own, purpose-built acoustic blast room to be built within their existing building.
​The new room, measuring approximately 13 metres long and 6 metres wide, provided a dedicated environment for Garic to carry out all their necessary industrial blasting. Their original blast pot investment lacked a suitable extraction system, but this was remedied by installing a reverse-pulse dust extraction system to remove airborne dust, which in turn ensured full visibility for operators during blasting.
​The aforementioned JBlast, despite its single use, was still prevalent in this new operation as the additional expense of a mechanical recovery system could not be funded alongside the blast room.
​Once the room was successfully installed, Garic could improve their working environment while retaining a blasting process they were comfortable with. It also provided them with a platform for future upgrades if and when the commercial case became stronger.
2024: Upgrading the blast room to meet growing production demands
Finding a more efficient approach as production demand increased
Fast forward another few years to 2024, and Garic was anticipating yet another substantial increase in its production workload that would double its existing throughput.
​Such a significant increase in blasting activity would also mean purchasing significant amounts of JBlast and disposing of ever larger quantities of spent abrasive.
​With the help of our technicians, SurfacePrep worked with Garic to review the costs of the then-existing process to identify where the operation could be more efficient.
​The proposal that was produced as a result of this review focused on introducing mechanical recovery equipment into the existing blast room that was installed in 2020 to allow Garic to retain its blast machine and extraction system while allowing for necessary adjustments to how the abrasive was handled and reused.
Introducing a heavy-duty abrasive recovery and recycling system
SurfacePrep specified a heavy-duty, U-configuration screw conveyor recovery system that would help to recover the spent abrasive from the blast room floor. The partial-floor arrangement features longitudinal conveyors that move collected abrasives towards a cross conveyor that feeds it into a belt and bucket elevator.
​The elevator transports the abrasive into a unit that cleans and separates the necessary media. Oversized contamination is removed by a rotary screen, while an airwash system separates dust and other unwanted particles.
​The abrasive, now clean of debris, is collected in a three-tonne storage hopper and ready to return to the blast machine for reuse. This resulting recycling process reduces the need for constant replenishment using fresh abrasives.
​This new recovery equipment meant Garic could significantly advance its blasting operation without replacing the entire installation.
From disposable JBlast to recyclable steel grit: the operational benefits
One of the most significant changes Garic made was transitioning from expendable JBlast to recyclable steel grit. Whereas abrasive was used once before being disposed of, the new recovery and separation system could clean and return steel grit to the blasting process repeatedly.
​Despite steel grit being a more expensive up-front abrasive, its longer usable life reduced overall abrasive consumption. SurfacePrep estimated that the steel grit could be used and reused a minimum of 20 times before having to be replaced.
​The savings were also felt outside the blast room, too. The lower abrasive consumption reduced the volume of material that needed to be delivered to the site, helping control transport costs.
​The recovery and cleaning process helped to reduce the amount of spent abrasives that needed to be disposed of. SurfacePrep also supported Garic with any used-media collection and recycling should it be required.
​With the new recovery system clearing the grit of unwanted fines and contamination, Garic benefited from a cleaner blasting process, better operator visibility, and a reduction in rework.
​When compiled together, the improvements were well timed in light of Garic’s production growth, as the costs associated with continuing to use single-use abrasives would have risen exponentially with increased blasting activity.
Financial comparison
|
Amount
| ||
|---|---|---|---|
2023 JBlast supply and estimated disposal costs
| £40,207.50 | ||
Estimated equivalent annual steel grit supply and disposal costs | £9,689.90 | ||
Potential annual saving at existing throughput | £30,517.60 | ||
Potential annual saving if throughput doubled | £61,035.20 |
Ongoing servicing to protect Garic's investment
Garic’s relationship with SurfacePrep continues to this day through regular maintenance and servicing agreements to support its blasting equipment.
​Scheduled maintenance helps to keep the mechanical recovery equipment operating as expected, with opportunities to identify wear or developing faults before they cause issues with production.
​This managed agreement also includes testing of the local exhaust ventilation system that supports the continued effective operation of the blasting environment. This kind of technical support is especially important when blasting is a key cog in the production schedule as it helps businesses such as Garic maintain output and plan with greater confidence.
A phased investment that supports Garic's future growth
The journey Garic has taken shows how blasting operations can be improved progressively, with investment being made as and when it is commercially sensible.
​By helping Garic turn their initial set-up into a more efficient, recoverable abrasive system, Hodge Clemco (now part of SurfacePrep UK) has supported the company’s changing production requirements.
Should you be looking to improve your industrial blasting operation, reach out to our technical specialists today. They can assess your existing setup before exploring options for improving efficiency and reducing abrasive waste, all to help support future production requirements.
