Featured Engineered to Order Manufacturing Solutions

Indexing automated cabinet, 4 blast stations, Part Rotation, cyclone reclaim, suction blast, RPH dust collector, Allen Bradley controls

Metal Lighter Bodies Preparation

Zippo, the legendary manufacturer of windproof lighters, required a precision-controlled blasting solution to prepare metal lighter bodies for final polishing, coating, and branding. The goal was to create a uniform, smooth surface finish on lightweight metal casings—typically brass or stainless steel—without damaging structural integrity or affecting fine tolerances. The solution needed to support high-volume production, ensure cosmetic consistency, and be optimized for fine, lightweight blasting media like glass bead or aluminum oxide.
Clemco worked in close collaboration with Zippo’s manufacturing and quality teams to develop an application-specific cabinet system that aligned with both functional and aesthetic standards. The design process included:
- Testing various lightweight abrasive media types and blast pressures to achieve a clean, matte finish without etching or warping
- Engineering ergonomic cabinet enclosures tailored to the size and handling of small metal parts
- Incorporating adjustable blast nozzles and airflow controls to support precise media delivery
- Designing custom part holders and fixturing to allow rapid changeovers and consistent positioning of lighter bodies
- Ensuring system durability and ease of maintenance for 24/7 production line readiness
Clemco delivered a set of compact, application-specific blast cabinets designed for Zippo’s high-volume finishing operations, featuring:
- Fine-tuned blast systems optimized for lightweight media to deliver controlled surface texturing
- Low-pressure, high-precision nozzle assemblies for consistent, cosmetic-grade finishes
- Quick-change fixturing and internal lighting to maximize operator visibility and reduce downtime
- Durable, easy-to-clean interiors designed to handle repetitive small-part blasting without contamination
- Optional integration with media reclaim systems to support clean, efficient operation with minimal media loss
The result was a reliable and efficient blasting solution that helped Zippo maintain the iconic look and feel of their metal lighter bodies, streamline their finishing workflow, and uphold their reputation for craftsmanship and quality at scale.

Single station automated cabinet, Part Rotation, Vertical nozzle oscillator, cyclone reclaim, suction and pressure blast, RPH dust collector, Allen Bradley controls

Overhead Lift
Component Blasting

One of the world’s foremost overhead lift manufacturers required a series of precision-engineered blast cabinets to prepare high-stress metal components—such as casings, vanes, and housings—for final assembly. The goal was to achieve uniform, contamination-free surface finishes that enhance fatigue resistance, coating adhesion, and dimensional reliability. These components operate under extreme temperature and pressure, making surface integrity a mission-critical quality requirement. The system needed to support tight tolerances, meet industry standards, and ensure repeatable results at scale.
Clemco partnered with the customer’s engineering and quality control teams to co-develop application-specific cabinet systems aligned with industry specifications. The design phase included:
- Conducting detailed evaluations of each component type’s geometry, alloy composition, and surface prep specification
- Selecting specialized media (e.g., aluminum oxide, steel grit, or glass bead) and configuring blast pressure, flow, and nozzle type to match part-specific needs
- Engineering multi-axis nozzle systems and adjustable fixturing to accommodate complex part contours
- Integrating HEPA-grade dust collection, media reclaim systems, and interior lighting to ensure clean, efficient operation
- Designing a robust HMI interface with recipe-driven controls, allowing technicians to select pre-programmed settings by part type for consistency and traceability
Clemco delivered advanced, commercial-grade blast cabinets, purpose-built for part preparation, including:
- Custom-configured blasting chambers with precision-controlled nozzles and media flow tuned for delicate yet demanding metal surfaces
- Programmable HMI systems for recipe selection, ensuring consistent blast parameters across multiple shifts and part variations
- Ergonomic loading and part handling systems to reduce operator fatigue while supporting complex, high-value components
- Media classification and dust collection systems to maintain abrasive purity and protect sensitive components from contamination
- Compliance with aerospace QA protocols, including documentation readiness for audits and production traceability
The result was a turnkey surface prep solution that enabled the customer to confidently process critical components for final assembly, ensuring high-performance reliability in mission-critical jet engine systems while maintaining repeatability, traceability, and aerospace compliance.

Clemco's line of Abrasive tumble cabinets in grey for blasting large quantities of small parts at one time

A top-tier U.S. manufacturer of industrial-grade fasteners required a reliable and high-throughput blasting solution to prepare bolts, screws, anchors, and threaded components for final zinc coating. The objective was to ensure uniform, clean surface textures that promote strong coating adhesion, minimize coating failure risk, and ultimately extend the usable lifespan of fasteners used in construction, energy, infrastructure, and heavy industry applications. The system needed to accommodate high part volumes, support batch and continuous flow processes, and deliver repeatable surface results across a wide range of fastener types.
Clemco worked closely with the manufacturer’s operations and quality teams to create application-specific blast cabinets tailored to fastener prep workflows. The design process involved:
- Analyzing fastener sizes, shapes, and alloy types to determine optimal media selection (such as steel grit or aluminum oxide) and blast pressure settings
- Designing high-capacity blast cabinets with adjustable rotary baskets, vibrating trays, or part tumblers to efficiently handle mixed batches without jamming or damage
- Incorporating precision abrasive metering and reclaim systems to maintain surface consistency and media efficiency
- Developing intuitive operator controls and programmable cycles for consistent blast performance with minimal manual adjustment
- Engineering cabinets for easy access, maintenance, and continuous-duty operation in high-output manufacturing environments
Clemco delivered a series of robust, production-grade blast cabinets specifically engineered for industrial fastener surface preparation, including:
- Rotary drum or vibratory basket loading systems designed to process large volumes of small-to-mid-sized fasteners efficiently
- Consistent, high-velocity abrasive delivery to create a clean and roughened surface profile optimized for zinc coating adhesion
- Media recovery and dust collection systems to maintain clean operation, extend media life, and protect part integrity
- Durable cabinet construction capable of handling the abrasiveness of steel grit while supporting round-the-clock usage
- Optional HMI controls with recipe storage for easy operator training and fast changeovers between product types
The result was a high-efficiency blasting solution that helped the manufacturer deliver corrosion-resistant fasteners with longer service life, tighter process control, and lower rework rates—supporting their reputation for quality in demanding industrial environments.