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Views: 0 Author: Site Editor Publish Time: 2026-03-14 Origin: Site
Client Background: A leading jewelry manufacturer specializing in precision polishing of 18K gold, sterling silver, and gem-set jewelry, with annual production value of approximately 50 million yuan and 80 employees.
Pain Points: Traditional manual polishing resulted in low efficiency, unstable quality, and difficulty meeting peak season order demands.
Solution: Deployment of CD-500 Centrifugal Disc Polishing Machine with customized media and process optimization, enabling automated batch polishing.
Key Results:
200% efficiency improvement (from 30 pieces/hour to 90 pieces/hour)
Yield increased from 85% to 98%
60% reduction in unit polishing cost
40% reduction in labor requirements (from 10 workers to 6 workers)
Industry: Precision jewelry manufacturing
Company Size: 80 employees, 50 skilled workers, annual production value of 50 million yuan
Primary Business:
Precision polishing of 18K gold rings and necklaces
Batch polishing of 925 silver jewelry
Post-processing of gem-set jewelry
Quality Requirements: Surface roughness Ra ≤ 0.4μm, no scratches, mirror finish luster ≥ 90
Production Challenges: Peak season orders (pre-Chinese New Year, Valentine's Day) are 2-3 times higher than normal, traditional manual polishing cannot meet capacity demands
Low Manual Polishing Efficiency, Severe Capacity Bottleneck
Impact: Unable to meet peak season order demands, often requiring overtime work until 10 PM, with order delays still occurring. Approximately 200 pieces affected daily, resulting in potential annual order loss of 8 million yuan.
Unstable Product Quality, 85% Yield Rate
Impact: 15% defect rate requires rework or scrap, causing direct annual loss of approximately 750,000 yuan; high customer complaint rate affects brand reputation. Daily production of 15-20 defective pieces, average rework time of 30 minutes per piece.
Rising Labor Costs, Difficulty Recruiting and Retaining Skilled Polishers
Impact: Polisher salaries increased from 6,000 yuan/month in 2018 to 12,000 yuan/month in 2024, but recruitment difficulty increased annually. 30% annual turnover rate, new worker training requires 3-6 months to reach proficiency level.
Difficult Polishing of Complex Structures, Hard-to-Reach Areas
Impact: Fine gaps and grooves in complex gem-set jewelry are difficult to polish thoroughly, affecting overall product quality. Approximately 30% of complex structure products require additional manual touch-up polishing.
Technical Requirements:
Surface roughness Ra: ≤ 0.4μm (achieving mirror finish)
Processing speed: 80-100 pieces per hour during peak season
Applicable materials: 18K gold, 925 silver, copper, stainless steel
Workpiece dimensions: 2-50mm (rings, pendants, earrings, etc.)
No damage: Must not damage gem setting structures or scratch metal surfaces
Business Requirements:
Equipment payback period: ≤ 12 months
Maintenance costs: ≤ 5% of equipment purchase price annually
Delivery time: Within 45 days after order confirmation
Training: Provide complete operational training, ensuring new employees can operate within 1 week
Equipment Model: CD-500 Centrifugal Disc Polishing Machine
Eddy Flow Advantage: Utilizing high-speed rotation to generate eddy flow effects, workpieces and media achieve high-speed friction in enclosed space, polishing efficiency is 15-30 times that of traditional vibratory polishing
Strong Batch Processing Capability: Can process 50-80 pieces per cycle, suitable for client's peak season large-batch production needs
Gentle Polishing Characteristics: Eddy flow action is uniform, will not damage gem setting structures, particularly suitable for precision jewelry
High Automation: PLC intelligent control, timing, speed regulation, media dispensing - all one-touch operation
| Parameter | Value | Description |
|---|---|---|
| Processing Capacity | 50L/batch | Can process 50-80 jewelry pieces, suitable for 2-50mm workpieces |
| Efficiency Improvement | 15-30x | Compared to traditional manual polishing or vibratory polishing |
| Applicable Materials | Gold, Silver, Copper, Stainless Steel | Covers all client material types |
| Power | 5.5kW | Moderate energy consumption, energy-efficient and eco-friendly |
| Dimensions (L×W×H) | 1200×800×1500mm | Small footprint, flexible placement |
| Weight | 350kg | Stable and reliable, smooth operation |
| Control Method | PLC Touch Screen | Simple operation, adjustable parameters |
| Timing Accuracy | 1 second | Precise control of polishing time, ensuring consistency |
September 15, 2024 - Requirement confirmation and on-site survey
September 20, 2024 - Solution design and equipment customization
October 25, 2024 - Equipment manufacturing and factory debugging
November 5, 2024 - On-site installation and operational training
November 12, 2024 - Trial production and parameter optimization
November 15, 2024 - Official production launch
Step 1: Process Flow Optimization Design
Integrate centrifugal disc polishing machine into client's existing production line:
Feeding Area → Pre-cleaning (degreasing) → Centrifugal Polishing → Secondary Polishing (fine finish) → Ultrasonic Cleaning → Inspection → Packaging
Set up material buffer area at polishing station to ensure continuous production; design specialized turnover containers to avoid scratching post-polished products.
Step 2: Polishing Media Selection and Ratio
Customize media solution for three materials: 18K gold, 925 silver, and copper:
| Material Type | Rough Polish Media | Fine Polish Media | Polishing Agent | Processing Time |
|---|---|---|---|---|
| 18K Gold | Ceramic beads Ø3mm (60%) | Stainless steel pins Ø0.5mm (80%) | Gold jewelry polishing compound | 5 min + 3 min |
| 925 Silver | Ceramic beads Ø2mm (50%) | Stainless steel pins Ø0.3mm (85%) | Silver jewelry polishing compound | 4 min + 2 min |
| Copper | Aluminum oxide grit Ø1mm (40%) | Polishing cotton (90%) | Copper jewelry polishing wax | 6 min + 4 min |
Step 3: Operational Training
Training subjects: 3 senior polishers + 2 new employees
Training content: Equipment operation, media ratio, parameter adjustment, daily maintenance, safety protocols
Assessment criteria: Theory exam (90+ points) + Practical assessment (independently complete 10 polishing batches, 95%+ yield)
Training outcome: All passed, new employees reached proficiency within 1 week
Step 4: Trial Production and Parameter Optimization
Day 1-2: Conduct 30 batch tests for each material, adjust time, speed, and media ratios
Issue encountered: Initial silver jewelry showed slight oxidation discoloration
Solution: Added antioxidant, shortened rough polishing time, extended fine polishing time
Final parameter confirmation: Met client quality requirements, batch stability excellent
Challenge 1: Risk of Gem Loosening in Complex Set Jewelry
Problem Description: During initial testing, small gems in set rings showed signs of loosening
Solution:
Adjusted media ratio, reduced large particle media during rough polishing stage
Reduced rough polishing speed (from 1800rpm to 1500rpm)
For set jewelry, added pre-inspection step, reinforced any loose gems beforehand
After adjustment, gem loosening rate decreased from 8% to 0.5%
Challenge 2: Small Workpieces (2-5mm) Easily Trapped in Equipment Gaps
Problem Description: Earring components and other small workpieces easily got stuck at discharge ports or turntable gaps during polishing
Solution:
Customized specialized filter screen (2mm aperture), preventing small workpieces from falling into collection tank
Designed specialized container (small bucket + gauze), loading small workpieces in batches before feeding into equipment
Added discharge inspection step to ensure no omissions
Challenge 3: Inconsistent Polishing Results Across Batches
Problem Description: Within same batch, workpieces at different positions showed uneven polishing results
Solution:
Optimized workpiece feeding method, avoiding stacking in one area
Limited each batch to 50 pieces or less (originally planned 80)
Added mid-process agitation (stop machine and stir every 2 minutes)
Ultimately achieved batch consistency standard deviation < 0.05μm
Innovation 1: Specialized Media Formula for Jewelry Industry
Technical Details: Traditional polishing media easily causes scratches on jewelry surfaces. We developed a "soft-hard-soft" three-stage media combination:
Deburring Stage: Medium-hardness ceramic beads for rapid deburring
Polishing Stage: Ultra-fine stainless steel pins for mirror finish
Protective Finishing Stage: Polishing cotton + polishing wax for increased luster
Result: Surface roughness reduced from Ra 0.8μm to Ra 0.35μm, no scratches
Innovation 2: Workpiece Classification and Path Optimization
Technical Details: Classified workpieces into 6 categories based on material, size, and complexity, establishing standardized polishing paths and times for each type
Result: Production efficiency improved 20%, no need for trial-and-error each time
Innovation 3: Rapid Quality Inspection System
Technical Details: Equipped with handheld gloss meter and microscope, sampling 5 pieces per batch, completing quality assessment within 3 minutes
Result: Abnormal batches detected immediately, defect rate controlled within 2%
Efficiency Improvement:
Processing speed: From 30 pieces/hour (manual) → 90 pieces/hour (automated) 200% improvement
Unit cost: From ¥12/piece → ¥4.8/piece 60% reduction
Labor requirement: From 10 workers → 6 workers 40% reduction
Peak season overtime: From average 60 hours/person/month → 20 hours/person/month 67% reduction
Quality Improvement:
Yield rate: From 85% → 98% 13 percentage points improvement
Surface roughness: From Ra 0.8μm → Ra 0.35μm 56% improvement
Consistency: Standard deviation from 0.12μm → 0.04μm 67% improvement
Customer complaint rate: From 3.5% → 0.8% 77% reduction
Return on Investment:
Equipment investment: ¥68,000 (CD-500 equipment) + ¥12,000 (customized media and training) = ¥80,000
Annual cost savings:
Labor cost savings: 4 people × ¥12,000 × 12 months = ¥576,000
Material cost savings: (12-4.8) × 150,000 pieces/year = ¥1,080,000
Defect reduction savings: 750,000 × (98%-85%) = ¥97,500
Total annual savings: ¥1,753,500
Payback period: 2.2 months
Annual ROI: 2,092%
| Metric | Before Implementation | After Implementation | Improvement |
|---|---|---|---|
| Daily Production | 240 pieces | 720 pieces | +200% |
| Unit Processing Time | 2 minutes | 0.67 minutes | -67% |
| Defect Rate | 15% | 2% | -87% |
| Energy Consumption per Piece | - | 0.05kWh | - |
| Floor Space | 20m² (10 workstations) | 5m² | -75% |
| Peak Season Overtime | 60 hrs/person/month | 20 hrs/person/month | -67% |
| Annual Labor Cost | ¥1,440,000 | ¥864,000 | -40% |
Working Principle of Centrifugal Disc Polishing Machine:
The centrifugal disc polishing machine utilizes a high-speed rotating disc to drive polishing media and workpieces, forming intense eddy flow motion within an enclosed polishing chamber. Key technical parameters include:
Eddy Flow Intensity Formula:
F = m × ω² × r
Where:
F: Centrifugal force
m: Total mass of workpiece + media
ω: Angular velocity (rotational speed)
r: Rotational radius
Three-Dimensional Motion: Workpieces in eddy flow not only revolve around the disc center but also rotate and tumble, ensuring uniform force on all surfaces
Gentle Polishing: Unlike traditional vibratory polishing's intense impact, eddy flow polishing is "friction + rolling" action that won't damage gem settings
Extremely High Efficiency: In enclosed space, contact area between media and workpieces is 10-20 times that of traditional methods
Rough polishing stage: 1500-1800rpm, rapid deburring
Fine polishing stage: 1200-1500rpm, precision finishing
Protective finishing stage: 800-1000rpm, increased luster
| Material | Rough Polish Media | Fine Polish Media | Polishing Agent | Processing Time | Speed | Workpiece Feed |
|---|---|---|---|---|---|---|
| 18K Gold | 3mm ceramic + 0.5mm pins | 0.5mm pins + cotton | Gold polish 5% | 5+3 min | 1600+1200 | 40-50 pcs |
| 925 Silver | 2mm ceramic + 0.3mm pins | 0.3mm pins + cotton | Silver polish 8% | 4+2 min | 1400+1000 | 50-60 pcs |
| Copper | 1mm alumina + ceramic | Cotton + 0.2mm pins | Copper polish 6% | 6+4 min | 1700+1100 | 60-70 pcs |
Day 1: Basic parameter testing, silver jewelry showed oxidation → added antioxidant
Day 2: Adjusted speed and time, quality stabilized
Day 3: Small batch trial production, discovered gem loosening → reduced rough polishing speed
Days 4-5: Continuous 50-batch testing, yield rate stabilized at 96-98%
Day 6: Mass production, parameters finalized
Fixed workpiece count per batch (within ±2 pieces)
Use electronic scale to weigh media, ensuring precise ratio (within ±2%)
PLC program automatically records batch parameters (time, speed)
Print parameter label after each batch, attach to turnover container
First Article Inspection: Before each batch begins, insert test piece, inspect immediately after completion
Process Sampling: Every 5 batches, sample 2 pieces, measure gloss and roughness
Routine Inspection: Quality inspector visits every 2 hours, checks equipment status and workpiece quality
Final Inspection: After each batch completion, sample 5 pieces, only pass to next process after qualification
Gloss < 90: Extend fine polishing time by 1-2 minutes
Surface scratches: Replace media, check equipment interior
Gem loosening: Notify setting workshop for reinforcement, reduce speed
Batch overall unqualified: Suspend production, adjust parameters and retest
Dear Team,
First, thank you for providing the professional polishing solution. Since the equipment went into production, both our production efficiency and product quality have shown significant improvement.
During our cooperation, we particularly appreciate the following:
Professional Technical Capability: From requirement survey to solution design, you demonstrated profound professional expertise. The customized media formula and polishing path optimization solution specifically for the jewelry industry exceeded our expectations.
Rapid Response Service: When issues arose during trial production, your engineers arrived on-site the same day to analyze the problem and find solutions together with us.
Superior Product Quality: Equipment operation is stable with extremely low failure rate. More importantly, polishing quality is very uniform, with yield rate increasing from 85% to 98%.
Comprehensive Training System: The training you provided was very systematic, and our employees quickly mastered operation essentials. Now even new employees can independently operate equipment within a week.
Data speaks best: payback period of only 2.2 months, annual ROI exceeding 2,000%. Based on this successful cooperation experience, we plan to add a second unit in 2025 and look forward to establishing a long-term strategic partnership.
Thank you again for your professional service!
— Production DirectorDeep understanding of client needs: Comprehensive preliminary research accurately identified core pain points (efficiency, quality, cost)
Customized solution: Provided customized media and processes addressing jewelry industry specificity
Full technical support: Participated throughout from solution design to trial production optimization
Comprehensive training system: Systematic training enabled clients to quickly master operation
Quantified outcome tracking: Detailed recording of each data point proved effectiveness and provided basis for future optimization
Standard parameters for jewelry industry can serve as reference template for similar clients
"Three-stage polishing media" solution can be extended to other precision metal processing fields
Small workpiece anti-jamming solution applicable to all small-batch precision processing scenarios
Rapid quality inspection system can be promoted as value-added service
Future consideration of adding automatic loading/unloading systems for further automation enhancement
Development of smarter quality inspection systems (machine vision + AI)
Exploration of mixed-material polishing possibilities for further efficiency improvement
Client interview videos can be planned in advance, aiming for simultaneous filming during equipment installation
| Item | Value |
|---|---|
| Equipment Model | CD-500 |
| Production Launch Date | November 15, 2024 |
| Client Industry | Precision Jewelry Manufacturing |
| Primary Materials | 18K Gold, 925 Silver, Copper |
| Workpiece Dimensions | 2-50mm |
| Daily Production | 720 pieces (240 pieces pre-implementation) |
| Yield Rate | 98% (85% pre-implementation) |
| Surface Roughness | Ra 0.35μm (0.8μm pre-implementation) |
| Operators | 6 people (10 people pre-implementation) |
| Equipment Investment | ¥80,000 |
| Annual Cost Savings | ¥1,753,500 |
| Payback Period | 2.2 months |
Company: Norden Machinery
Email: hznorden@gmail.com
Phone: +86-13625726381
Website: https://www.nordenmachine.com/
