A U.S.-based power generation manufacturer partnered with Bel Air to develop a complete finishing system for large airfoil components used in gas-powered turbine systems.

These parts, ranging from 95 to 180 pounds and up to 3 feet in length, required a controlled finishing process that could improve surface consistency while protecting critical areas of the component. In addition to the finishing process itself, the system needed to support production throughput, automate wastewater handling, and minimize operator involvement.

Objective

Develop a full-system solution to process large airfoil components, improving surface consistency while protecting critical features, increasing throughput, and automating material handling and wastewater treatment.

The Challenge

Large unprocessed airfoil component in crate at Bel Air Finishing warehouse prior to vibratory finishing

Large airfoil component prior to finishing, highlighting part size and handling constraints.

Processing large airfoil components presents several challenges:

  • Part Size & Weight — Components ranging from 95–180 lbs limit handling and processing options
  • Critical Surface Protection — Select areas must be shielded from media contact during finishing
  • Manual Process Limitations — Traditional methods are time-intensive and inconsistent
  • Wastewater Management — Abrasive byproducts require controlled collection and treatment

The customer’s production target was approximately two parts per day, requiring a solution that could improve both efficiency and consistency.

Solution

Bel Air FMT-80 Large Series Industrial Vibratory Tub

FMT-80 Industrial Vibratory Tub

Bel Air designed and manufactured a complete finishing system centered around a large-capacity vibratory tub, integrated fixturing, and automated wastewater treatment.

Custom fixturing was developed to secure the airfoils during processing while protecting critical areas that could not be exposed to media contact. The fixturing also improved part movement within the vibratory process, increasing finishing efficiency and reducing cycle times.

The system utilizes an 80 cubic foot vibratory tub capable of processing two large airfoils simultaneously. Abrasive media, combined with controlled water and compound dosing, enables consistent surface refinement across the part while maintaining geometry.

To support continuous operation, Bel Air integrated a closed-loop material handling system. Process water and debris are transferred to an accumulation tank, then automatically fed into a high-speed centrifuge. The centrifuge separates solids from the liquid stream, continuously discharging waste while returning treated water for reuse or downstream processing.

The entire system is designed for automated operation. When the vibratory process is running, water flow and treatment are activated automatically, minimizing operator intervention and ensuring consistent process control.

The result is a scalable, production-ready system that:

  • Increases throughput to support customer’s target of ~2 parts/day, with capacity for 4–6 parts per shift
  • Improves consistency across large airfoil surfaces
  • Protects critical features through custom fixturing
  • Automates wastewater handling and reduces manual labor
  • Enables repeatable, hands-off operation.

Engineered Finishing Systems

Large, complex components require more than a single machine—they demand a fully engineered finishing system.

Bel Air Finishing designs complete process solutions tailored to your parts, combining equipment, custom fixturing, media, and automation to deliver consistent, production-ready results at scale.

Get a Process Evaluation

Working with large or complex parts? Send us your parts for a FREE evaluation, and we’ll develop a finishing system tailored to your application.