Cost Reduction through better Processes

Sanding and polishing processes offer far greater savings potential than it may initially seem. Studies conducted at the Menzerna Technical Center show that working on more efficient processes and higher quality yields significantly more benefits than lowering purchasing prices. Shorter processing times and reduced product consumption at equal or better quality - these are the goals that Menzerna application technicians aim to achieve together with their customers.

Challenges in Cost Structure
The total costs of an automated sanding or polishing process are typically split evenly between variable and fixed costs. Around 90% of the variable costs arise from energy, labor, and maintenance. These cost components can therefore be influenced through better process control. Consumables such as sanding belts, polishing rings, and polishing compounds make up only a small portion of the cost structure. The leverage for savings in this area is therefore much weaker. Nevertheless, optimization efforts often begin with material purchasing, even though the impact on total costs is limited.

Two Ways to Reduce Costs

Procurement-Oriented Approach
Price comparisons, tenders, and sampling primarily affect consumables. However, this category accounts for only 7% of variable costs and just 3.5% of total costs. Consequently, the savings potential is limited.

Process-Oriented Approach
Far more effective is focusing on reducing consumption volumes, shortening processing times, and improving process stability. A simple calculation illustrates the concept: a workpiece is polished on a flatbed machine. The polishing roller requires five passes to achieve the desired gloss level. If the number of passes can be reduced to four, this results in a remarkable 20% increase in productivity. In practical terms, this could mean eliminating one out of five machines — or gaining 20% more capacity without investing in additional equipment.

Real-world experience shows that results comparable to this simple example are indeed achievable. By replacing a conventional emulsion with Menzerna’s EM 291 polishing emulsion, one customer was able to reduce processing times for aluminum parts by 55% and cut compound consumption in half - without compromising quality. Savings of this magnitude cannot be achieved through traditional price comparisons of materials.

Added Value Through Menzerna
Results like these are regularly achieved when Menzerna products are introduced. Menzerna’s process-oriented approach sustainably reduces costs, improves process stability, increases output, and ensures consistently high quality - a clear advantage for competitiveness.