At the Test Center of the Reutlingen headquarters, tests are conducted to determine which brush, in which configuration, is best suited for processing a specific component or workpiece.
Customers can send in their samples to be tested in stress tests, long-term test series, and application trials using various fill materials.
There is currently hardly any tool or machine element that covers such a wide range of applications as the technical brush. Versatile and adaptable in its design, it repeatedly proves to be the optimal solution for tackling even demanding tasks in industry and trade. Developing new, custom-made brush types on a regular basis is therefore part of the daily business for the experts at KULLEN-KOTI. This is done in close coordination with customers, with the machinery of the Test Center at the Reutlingen headquarters optionally playing a central role.
Almost 150,000 brush variants can currently be found in the portfolio of manufacturer KULLEN-KOTI. However, the application potential of this tool — which is both a machine and a component — is far from being fully explored.
At the Reutlingen site alone, the development of new brush types and the project-specific modification and configuration of established variants make up a large part of the daily work of the brush experts.
Sometimes the focus is on innovative solutions for the application of powdery substances, or on tools for deburring and edge rounding, or for removing paint and adhesive layers; other times, conveying or positioning tasks are the focus, or products need to be cleaned, openings sealed, or surfaces dusted.
The goal is always the same: to realize the optimal brush system for the customer’s specific application.
On the way to achieving this, numerous factors must be taken into account. For example, aspects of process adaptation (How fast should the brush rotate?), process integration (Does the brush fit into our machine?), workpiece compatibility (Is the fill suitable for the treated surface?), and cost-effectiveness (What is the brush’s service life?).
All these factors influence the specific design and configuration of the brush — such as the determination of dimensions, the construction of the carrier, the selection of the fill material, and the design of the interface for clamping a powered brush into a machine.
Expertise from Many Directions
The key prerequisite for ensuring that the consideration of all these factors ultimately leads to the optimal brush system is the high quality of consulting provided by the experts at KULLEN-KOTI.
For the customer, this is reflected in a combination of many years of practical experience and a broad spectrum of design and engineering know-how, which also includes in-depth knowledge of materials and processes.
These interdisciplinary competencies and the ability to deeply understand the customer’s processes lead to innovative solutions that go far beyond the user’s previous possibilities.
Because quite often, an optimally designed brush proves to be the more economical tool for material removal or application, the better transport or positioning element, or the more efficient sealing solution. Frequently, the experts at KULLEN-KOTI also identify potential for process optimization for their customers – for example, by replacing outdated tools with high-performance brush systems or by strategically integrating brush processing into existing production workflows. Thanks to the large number of already realized types and variants, it is often possible to achieve results within a very short time through minor modifications. Sometimes, it is merely the diameter of the brush, the thickness of the filaments, the density of the fill material, or the mechanics of the mounting that need to be adapted to a specific application.
Space for Creative Ideas
The space where many brush technology optimizations are verified or new developments are tested is the TestCenter of KULLEN-KOTI at the Reutlingen site. Here, expert professionals systematically investigate on modern production systems and testing machines which brush, in which design, is best suited for processing a component or workpiece. Customers can send in their samples to be tested in stress tests, long-term test series, and application trials with varying fill materials (steel wire, plastic, natural fibers, abrasive materials, etc.). Economic evaluations of different brush systems are also part of the process. Customers are welcome to participate in all of this in person. Especially in combination with the company’s consulting expertise and engineering know-how, the Brush TestCenter at KULLEN-KOTI offers the best conditions for developing the perfect brush solution, even for complex requirements.
Notably, users from the field of surface treatment frequently take advantage of this environment to test the performance of modern tool brushes for deburring tasks in individual tests or test series. They explore questions such as service life, removal performance, centrifugal force, or surface quality, or they test various geometries, fill materials, and fill lengths and their effects on different materials (steel, stainless steel, non-ferrous metals, and more). Upon request, KULLEN-KOTI also provides customers with comprehensive test reports.
Value-Creating Win-Win Partnerships
They are deburring tools, cleaning elements, sealing solutions, material flow components, and much more – the technical brushes from KULLEN-KOTI are now at the heart of countless applications in industry and trade. With a portfolio that is likely unique, offering nearly 150,000 different designs for virtually every area of application, the company provides unprecedented possibilities for configuring and selecting the optimal brush solution.
To make this enormous potential accessible to customers and users, KULLEN-KOTI offers a wide range of consulting expertise. This not only paves the way for quick product decisions but also opens up opportunities for value-creating win-win partnerships between the manufacturer and its customers.
For users, this often leads to insights that result in significant quality improvements and efficiency gains – for example, in manufacturing or conveying processes.