Category Archive: Blog

Brushes Wastewater Treatment

Wastewater facilities treat and process wastewater to acceptable thresholds for environmental reintroduction. The procedure consists of several steps, from testing and pumping to filtration and sterilization, each requiring specialized equipment. Special brushes in a variety of forms are needed depending on the intended processing stage.

For more than a century, the Cocker-Weber Brush Company has been considered a pioneering industrial brush manufacturer. We produce the best alternative to maximize your wastewater management facility’s operations by focusing on quality and innovation based on need and design discussions.

This article will guide you through the types and applications of brushes commonly used in wastewater facility treatments.

What Is the Wastewater Management Process?

Wastewater management — characterized as the collection, treatment, and reuse of wastewater — is an essential method of conserving water resources. Treatment facilities use special brushes for the following purposes:

Screen Cleaning

Screening equipment separates rags, wood shards, plastic materials, and grease from wastewater. The removed material is washed, pressed, and disposed of in a landfill, while the screened wastewater is pumped to the grit removal step.

Rake Cleaning

This process requires sturdy brushes as it segregates bulky matter carried by the water. If these substances are not removed, they can reduce the water effectiveness and sludge treatment or impede treatment operation and implementation.

Odor Control

This process necessitates highly durable and chemically resistant brushes since odor is unavoidable in most areas of a wastewater treatment facility. The primary issues comprise the immediate treatment and sludge handling, emitting ammonia, mercaptans, hydrogen sulfide, and skatoles, among many others.

Treatment Tank Temperature Regulation

This step utilizes brushes that can withstand extreme temperatures because most bacteria thrive at 68 °F to 95 °F. In addition, lower temperatures allow these microorganisms to work more slowly, but high temperatures can kill the bacteria and render the process ineffective.

Waste Transportation

Depending on its source, water can contain dissolved and suspended contaminants, including highly degradable organic substances, salts, heavy-metal compounds, and fertilizers. Brushes that are long-lasting and resistant to corrosion, chemicals, and extreme temperatures are used to ensure smooth waste transport.

Waste Separation

Separating suspended particles from wastewater using gravitational forces is known as wastewater clarification or sedimentation. Brushes with chemical resistance are used to treat colloidal solids during the separation process by coagulation and flocculation.

Sealing Gaps

Foam or bristle brushes are required in sealant applications as they are frequently used to keep leaks from penetrating gaps and polluting the soil and groundwater around them.

Types of Wastewater Brushes

Industrial brushes are designed to perform specific tasks and other applications during wastewater management. Among the most common brushes are the following:

Sewage Brushes

These brushes are used in sewage treatment systems to remove pathogenic organisms and microorganisms. They also filter out pollutants before they exit the tank and enter the ground.

Pipe Brushes

In plumbing applications, pipe brushes are used to clean pipes and other difficult-to-reach areas. Typically, they are attached to a long, thin metal piece you can insert deep into a pipe. The brush diameter should be equal to or greater than the pipe diameter.

Waste Brushes

Waste brushes remove as many suspended solids as possible before discharging the remaining water, known as effluent, back into the environment.

Sludge Brushes

This brush type is used to treat sewage sludge, a mud-like residue resulting from wastewater treatment. The sludge contains contaminants and pathogens such as bacteria and viruses. However, it could also have beneficial organic matter and nutrients like nitrogen and phosphorus, making it an excellent fertilizer or soil improver.

Wastewater Brushes

Wastewater brushes move and separate waste during the water treatment process. In this industry, they are also used to seal gaps and openings in any facility or processing equipment area.

Wastewater Brushes From Cocker-Weber

Cocker-Weber offers the following brush types appropriate for waste management applications:

  • Tufted Strip Brushes – 5 in. Long Strip Brushes : Tufted strip brushes are highly resistant to corrosion and work well in areas with restricted movement or no power source. They have plastic bases with holes for holding the bristles.
  • Custom Brushes: Cocker-Weber customizes brushes as some waste management applications need tailored equipment to meet specific requirements.
  • Spiral Round Brushes: Spiral round brushes are cylindrical and ideal for the high-speed removal of sticky or dried accumulations in wastewater management processes.

Exceptional Brushes From Cocker-Weber for Your Waste Management Needs

Are you in need of durable brushes for your wastewater management applications? Cocker-Weber got you covered! Regardless of your requirements, we can help you find the best solution for your application. We provide cylinder, wheel, disk, cup & end, and tufted strip & plate brushes for various industries and applications.

Contact us now to learn more about our wastewater brushes, or complete our online form for inquiries and additional information.

How To Choose The Best Brush Filament For Your Application

In many manufacturing processes, industrial brushes are used to clean, polish, deburr, or coat different products and components. There are hundreds of industrial brushes to choose from, but they are not all interchangeable. Finding the most suitable brush for your application is determined by your industry setting, application requirements, brush size, and the type of brush filaments to use.

Cocker-Weber Brush Company manufactures high-quality, US-made industrial brushes that are durable, innovative, genuine, and cost-friendly to use in the long term.

This article will guide you through the factors you should consider in choosing the best brush filament for your application. In addition, you will also learn about the extensive range of industrial brushes offered by Cocker-Weber.

What Is A Brush Filament?

Brush filament refers to the bristles or fibers that provide the working surface of the brush. With the many types of industrial brushes available, what makes each brush so different from the others is the type of filament materials used in each.

Common Types Of Brush Bristle Materials

Cocker-Weber Brush Company makes brushes from various metals, natural fiber, and synthetic materials. We can also custom-made brushes and brush filaments if your project demands a more specific requirement.
Here are the three most common brush filament materials:

  • Metals. Brushes with filaments made of metal materials are used in applications that require robust, sharp, and aggressive bristles, usually for deburring and cleaning. The most common metal filaments are made of brass, bronze, carbon steel, and stainless steel.
  • Natural Fibers. These filaments are soft, all-natural, and commonly used for painting applications. They include animal hair fibers such as Chungking bristles, white boar bristles, horse hair, and goat hair. There are also plant-based fibers like Tampico and agave.
    • Synthetic Materials. Filaments from artificial materials offer excellent bend recovery and are commonly used on applications that require damage tolerance and chemical resistance. These include nylon, anti-static nylon, PVC, polyethylene, and styrene.

Factors To Consider When Choosing A Brush Filament

With so many brushes to choose from, finding the right one for your application can be challenging. Therefore, it is crucial to keep the following considerations in mind when trying to select the proper brush filament for your application:

Filament’s Length & Diameter

A brush filament’s measurement is critical when choosing the suitable filament for your application. Shorter filaments are often stiff and are ideal for aggressive or heavy applications. On the other hand, longer filaments have more flexibility and are ideal to use for brushing uneven surfaces.

Generally, filaments are circular, but there are also a few alternative shapes of bristles. Usually, thicker filaments are more optimal than thin bristles when it comes to more aggressive applications like heavy-duty deburring.

Picking insufficient filament length or inappropriate bristle diameter for your specific application will cause early filament exhaustion, leading to the need for replacement, which is not cost-efficient if done habitually.

Filament’s Properties

Aside from the physical characteristics of the filament, you should also consider other properties such as:

  • Softness or Stiffness. Tensile modulus is a measure of the stiffness of the filament. The higher the tensile modulus, the stiffer the bristles. On the other hand, a filament’s ability to return to its original position after being bent is called bend recovery. Again, the application is a factor in determining if you need a soft or stiff filament.
  • Moisture Absorption. Some bristles have different levels of moisture absorption. For instance, natural fibers absorb moisture easily, which makes them not ideal for wet applications. In contrast, synthetic filaments retain their stiffness even after being soaked in liquid and are therefore, suitable for wet applications.
  • Chemical Resistance. Chemicals are frequently used in cleaning, sanitizing, and degreasing processes. Depending on their concentration, chemicals can degrade plastics or synthetic materials over time, resulting in filament damage.
  • Wear Resistance. The filament’s ability to resist being worn away easily is an important factor to consider when it comes to cost-efficiency. You should pick a bristle with high bend recovery and fatigue resistance which refers to how often the filament may be bent back and forth before it inevitably breaks.
  • Temperature Resistance. Some filaments will soften and melt over a range of temperatures. For instance, a UV light will result in the rapid degradation of synthetic materials with some polymers.

Brush Application Requirements

Choosing the best brush filament all comes down to its application. Analyzing your desired application is important to decide which filament to go for. Here are some common questions you should ask:

  • Will the brush be used aggressively, like scrubbing or deburring? Or will it be used gently in a conveyor system?
  • Will it be used in a dry or wet application? In high or low temperatures?
  • Is the brush going to be in contact with chemicals or solvents?
  • Will the process need a lot of bending, or will the brush remain stationary?
  • Will there be other elements or tools moving against the brush?

Your answers to these questions will help determine which filament length, diameter, property, and raw material will be the most suitable for your application.

Metal filaments are best suited for chemical shielding, abrasion resistance, electrical conductivity, and high-temperature applications. Some metal filaments can dissipate static charges, while others, like stainless steel, are suitable for food and pharmaceutical applications.

Natural fibers are mostly used for scrubbing, washing, and fine dusting. Tampico and other fibers can be stiffened for greasy applications and abrasive compounds. They usually come in various textures, lengths, and elasticity.

Finally, synthetic filaments are more widely available and cheaper than the other two. They are ideal for painting plasterboard, wood, concrete, masonry, tiles, and metal.

Need Help? Talk To The Brush Experts At Cocker-Weber

You can select from Cocker-Weber’s diverse industrial brushes suitable for your project. We offer different types of brushes and filaments such as cylinder & wheel brushes, cup & end brushes, flat & handle brushes, tufted, strips, & plate brushes, and other special brushes. You can send us your specifications, and we can create a custom brush solution for you.

We will work with you one-on-one to determine the best combination of fill, shape, and construction methods. Learn more about our products and solutions by visiting our website or contacting us directly.

You can also request a quote, and we can guarantee to produce high-quality custom-made brushes for your specific requirements.

How to Select Industrial Brushes

Industrial brushes serve a variety of purposes in virtually every business sector. 

Industrial Brush Types - Cylinder Wheel Brushes

From food and pharmaceutical products to material polishing, industrial brushes are critical to the speed, efficiency, and safety of many applications. Although they are often overlooked in industrial operations, quality brushes can make the difference when it comes to productivity and profitability.

At Cocker-Weber Brush Company, we pride ourselves on providing our industrial sector customers with exceptional industrial brushes for every purpose. We take an innovative approach to brush manufacturing, tailoring each of our brush designs to the changing needs of the industry. At the same time, we incorporate tried-and-true brush-making techniques and materials that have kept Cocker-Weber at the forefront of the industry for over a century. 

What are Industrial Brushes?

Industrial brushes consist of a core with bristles in a variety of shapes, including cylindrical, wheel, and flat configurations. They are specifically designed for industrial operations and should be an exact fit to the application for optimal performance. The size, shape, bristle material, mounting method, and core all vary widely depending on the intended use of the brush.  Industrial brushes should enhance your operations without applying undue pressure or compromising overall speed. 

Selecting Industrial Brushes

There are several factors to consider when selecting your industrial brushes, including service life, intended frequency of use, brush quality over time, and replacement options. Selecting the proper  brush will increase its longevity and ensure that it remains in good condition thoughout its lifespan. Other factors to consider include: 

  • Application Type: Consider the intended application, such as shielding, closing gaps, static dissipation, polishing, cleaning, and more.
  • Environment: Take into account the environment in which the brush will operate, including wet versus dry operations, chemical exposure, temperature fluctuations, and sunlight exposure. 
  • Operation Cycles: Calculate the amount of force and periods of operation that the brush will need to withstand. Heavy- and light-duty applications require significantly different brush needs. 
  • Physical Properties: Determine whether your application requires soft or aggressive brush bristles. 
  • Special Materials: Consider any special material and design requirements for compliance with the FDA and other regulatory bodies.

Types of Industrial Brushes

Click to Expand

How to Select Industrial Brushes

Industrial brushes come in a wide variety of shapes and sizes. Different types of industrial brushes include: 

  • Cylinder Brushes: Cylinder brushes consist of a series of bristles arranged at a perpendicular angle around a cylindrical core. The core is designed with a hollow center to easily attach shafts and rods for industrial use. Suitable for produce washing to conveyor belt cleaning.
  • Strip Brushes: Strip brushes are designed with a flat, rectangular core with bristles attached to one side. They are available in narrow tufted strip designs or wider plate brushes. Ideal for arranging products without damaging them.
  • Wheel Brushes: Wheel brushes have a disc-shaped core with bristles attached to the narrow outer edge perpendicular to the disc’s rotation. They are ideal for narrow, focused brush applications. 
  • Cup Brushes: Cup brushes feature bristles on one side of a flat, disc-shaped core parallel to the rotating axis of the disc. Shorter bristles, or no bristles in the center give the cup brush its signature shape.
  • End Brushes: End brushes are shaped like cup brushes but without the shorter center bristles. Both end and cup brushes are used to access small spaces and crevices. 
  • Conveyor Cleaning: Specifically designed for conveyor applications, industrial conveyor cleaning brushes are available in both strip and cylindrical designs. They are used to remove a variety of solid or liquid materials from conveyor belts, rolls, and other equipment.

Industrial Brush Applications

Industrial brushes are critical to a variety of operations. Some of the most common applications include: 

Industrial Processes

  • Welding and Surface Preparation
  • Painting and Coating Application
  • Metal Deburring and Polishing
  • Paint, Coating, and Rust Removal 
  • Surface and Thread Cleaning
  • Surface Finishing 
  • Glass Polishing and Production

Industries Served

  • Agriculture Manufacturing
  • Aerospace Manufacturing
  • Automotive Manufacturing
  • Food and Beverage Processing
  • Industrial Manufacturing and Fabrication 
  • Packaging Applications
  • Pharmaceutical Production
  • Printing Applications

Industrial Brushes from Cocker-Weber

Whether you need a conveyor brush for food processing or a small end brush for intricate detailing, Cocker-Weber has the solution for you! We offer a broad range of brush designs, from cylinder and wheel brushes to cup, end, disk, flat, strip, and plate brushes. For applications with special requirements, we also offer specialty and custom brushes to meet your particular needs. 

Visit our Industrial Brushes Page to learn more about our extensive selection. For more information on how our brushes can enhance your industrial operations, contact us today or request a quote

Industrial Rotary Brushes

Industrial rotary brushes are specifically designed so that the brush filaments rotate around a revolving axis. They are usually mechanically powered or automated for applications such as surface sweeping, automatic material polishing, and cleaning industrial conveyor systems. Rotary brushes are typically available in three designs: cylindrical, wheel-shaped, and cup-shaped brushes.

Types of Industrial Rotary Brushes

At Cocker-Weber Brush Company, we pride ourselves on providing the highest-quality industrial rotary brushes for numerous industries and applications. Our wheel, cylinder, and cup rotary brushes are available in a variety of sizes and materials to suit your unique needs.

Wheel Rotary Brushes

As the name implies, wheel rotary brushes consist of a flat wheel with brush filaments placed around the outer edge of the wheel. By definition, the width of the brush surface that contains the filaments must be less than the diameter of the brush. A wheel rotary brush is typically powered by a turning shaft or gear mechanism, depending on the application.

Cylinder Rotary Brushes

When the width of the filament brush surface is greater than the diameter of the central wheel, the brush is considered a rotary cylinder brush. Easily identified by their cylindrical shape, these brushes are composed of a central tube or bar that is covered on the outside with brush filaments. The core tube can be composed of a broad range of plastics, or even wood, and filaments are available in synthetic, natural, and metal materials. Industrial cylinder brushes are often used to clean conveyor belts, wash produce, polish finished products, and spread coatings such as paint or adhesive.

Cup Rotary Brushes

Cup rotary brushes are similar to wheel brushes, but the filaments of the brush are situated around one lateral edge of the disk instead of the outside edge. The brush filaments are oriented to point in one direction perpendicular to the axis of the wheel, creating a cup shape that leaves the other side of the wheel clear of filaments. Industrial cup rotary brushes are particularly useful for focused cleaning and polishing, and they can often be found on vacuum equipment and drill-powered rotary brushes.

Industrial Rotary Brush Materials

Cocker-Weber - Brush Company - IGCocker-Weber is pleased to offer industrial rotary brushes in a wide range of filament materials, including synthetic materials, metal, and natural fibers.

Synthetics

There are numerous synthetic materials available for use in industrial brushes. Nylon and polypropylene are the most common brush materials, as they create filaments that are extremely durable, waterproof, and chemical-resistant. Synthetic filaments are less expensive to manufacture than harvesting natural fibers and metal. They are also antimicrobial and easy to clean, which makes them ideal for food processing and in health care settings.

Metals

Metals used in rotary wire brushes include bronze, brass, stainless steel, and carbon steel. Bronze and brass filaments are often used to clean and polish items in applications that require electrical conductivity and corrosion-resistance. Stainless and carbon steels are stronger and used for burnishing and deburring highly durable materials.

Natural Fibers

Natural fibers for brush filaments are derived from both plant and animal sources, such as boar’s bristles, horse hair, goat hair, Tampico agave plants, bassine, and palmyra. These materials offer a variety of properties: Boar’s bristles, for example, are stiff, but goat’s hair is extremely soft. In general, natural fibers are less harsh on surfaces compared to metal filaments and are often used for delicate and sensitive surfaces. Even soft natural fibers are highly durable.

Contact Cocker-Weber for Your Industrial Rotary Brushes Today

Cocker-Weber is committed to providing superior-quality brushes in a broad range of designs and materials to meet the demands of any application. Whether you need a metal brush for industrial deburring or a soft natural brush to clean fragile materials, Cocker-Weber has the right design for you. To learn more about our extensive portfolio of industrial rotary brushes, contact our experts today and request a quote.

Polishing Wheel Brushes: How to Choose the Best for Jewelers Polishing

Wheel brushes allow manufacturers to create finishes that embellish the appearance of gems, metals, and other materials. These devices are valued by artisans and craftsmen for their ability to customize materials to fit their vision. Professionals can choose from a variety of wheel brushes and polishing wheels to achieve the look they want. For jewelry manufacturers, polishing wheel brushes are an integral part of the production process.

Wheel Brush Qualities and Applications

Wheel brushes are circular devices that attach to automated machine components. Rotary mechanisms control the speed of the brushes’ motion as they turn around a secured axis. This allows manufacturers to systematically strip away layers of materials to create cuts, patterns, designs, and special finishes. Some common applications for wheel brushes include:

  • Cleaning
  • Polishing
  • Deburring
  • Rust removal
  • Surface finishing
  • Weld blending

A variety of wheel brush designs exist that allow manufacturers to create specialized effects on the surface of their chosen medium. Size and format determine achievable results. The tiny bristles that surround the brush’s outer edge are made from a range of materials to fit their intended purpose. Some of these include:

  • Nylon filament
  • Brass filament
  • Stainless steel wire filament
  • Chungking bristle filament
  • Tampico filament

In jewelry making, wheel brushes help artists create cuts, polish stones, and blur away imperfections with both high speed and accuracy.

Polishing Wheel Brushes

Choosing the Best Polishing Wheel Brush

Cocker-Weber, a producer of high-quality wheel brushes and other devices used in industrial manufacturing processes, offers two lines of products geared specifically for those in the jewelry-making industry. Artisans and craftsmen enjoy the superior quality product line, as these tools help them craft exquisite and unique designs. For those who need value as well as precision, the standard quality line produces similar results with a more cost-effective material. Both product lines are made with Chungking bristles, which are known for being durable and effective. Our jeweler’s polishing wheel brush catalog includes:

These brush types are available with a 1-7/8 inch, 1-1/2″ or 1-1/4 inch hard maple hub and various trim sizes. Choose the size based on your product dimensions.

Brush Filling Options

Various filament options allow artisans to further control the look of their finished products.

  • Chungking bristles used in the early stages of polishing help heavily corrosive compounds, like Tripoli, to work more efficiently.

  • Stainless steel wire bristles are subtle for satin finishing softer materials like white gold, silver, and aluminum.

  • Brass wire wheel filling delivers a fine grade of polishing to gold, brass, and copper.

Bristle type is chosen based on the desired end result and the materials used during production.

Chungking Brushes

Our superior line of polishing brushes contain the highest quality bristles known as “Chungking Bristle”. Favored by craftsmen and artisans around the world, Chungking brushes are tightly bound bristles that are mounted into the hardwood hubs. They ensure a longer lifespan as well as a much higher quality polishing finish when all is said and done. 

Due to the rise in popularity, many fake duplicates have presented themselves over the years under a variety of different label names — including the Cocker-Weber brand itself. These fake brushes are often much lower in quality and construction — so much so that they often break after just one accelerated minute of wear (10,000 RPM at just 1-pound of pressure.) To make sure you’re getting the most out of your polishing brushes, make sure to contact Cocker-Weber directly!

Custom Wheel Brushes From Cocker-Weber

Cocker-Weber Brush Company produces variety of brushes for industrial applications. Our line of jeweler’s tools includes a range of trim sizes, bristle materials, and hub materials. Whether you’re looking to buy on a budget or demand the most superior quality results, our catalog contains the solution to your jewelry production problems. Contact us directly for a Jewelry Tool Distributor who can supply you with Cocker-Weber wheel brushes.

Industrial Cylinder Brushes: Applications and Materials

Cylinder brushes are typically mounted onto a shaft and spun using a motor. They can be made with denser filling materials or spiral-shaped materials to facilitate different types of product movement or brush intensity within a given application. These brushes go by many names, including:

  • Rotary brushes
  • Wound brushes
  • Spiral brushes
  • Coil brushes

Industrial Cylinder Brushes
(Click on image to enlarge.)

Cylinder Brush Industrial Applications

Cylinder brushes have many common industrial applications. For example, they may be used to facilitate simple cleaning operations in machinery. They can also be used to remove particles from chips, rust, and oil. Smaller, more delicate cylinder brushes can be used for sensitive applications, such as cleaning a computer’s circuit board before installation. The brushes reach into crevices on the board to ensure remove particles, dust, and other contaminants. Industries that use cylinder brushes include:

  • Medical Devices
  • Pipeline
  • Food processing
  • Circuit board manufacturing
  • Metallurgy
  • Glass and ceramics processing including Optical
  • Machine and automation applications
  • Plastics and Rubber processing
  • Aerospace

Common applications for cylinder brushes include:

  • Sorting and moving product for packaging
  • Polishing, cleaning, deburring or coating during production
  • Cleaning conveyor belts
  • Washing and waxing fruits and vegetables
  • Spreading glue or paint
  • Metal finishing
  • Texturing
  • Label applying
Industrial Cylinder Brushes
Industrial Cylinder Brushes
Industrial Cylinder Brushes

Choosing the Best Fill Material for Your Cylinder Brushes

Brushes can be made with different fill materials. Which is appropriate depends on the intended use. Some of the options include:

  • Stainless steel. These brushes are used on products fabricated from stainless steel and aluminum, in applications that include direct contact with food, and in high-heat situations.
  • Brass. Softer than stainless steel, brass provides a brushing action that doesn’t scratch harder metals. This material is ideal for cleaning in production environments, such as conveyor cleaning.
  • Nylon. Nylon brushes are commonly used for scrubbing, dusting, and cleaning conveyor belts. Applications include bakery and food conveyor belts, plating processes, and lumber mills.
  • Goat hair. Goat hair is very fine and soft, making it ideal for short, soft brushes, such as those used in the electronics industry.
  • Horsehair. Horsehair brushes are ideal for fine dusting, cleaning, and polishing applications. 
  • Tampico fiber. These brushes feature greater water absorption and retention than synthetic brushes; have good heat resistance; and can be used wet or dry for scrubbing, washing, and polishing.

Cylinder Brushes from Cocker-Weber Brush Company

Cylinder brushes can be used in thousands of applications throughout abroad range of industries. Brushes are available with different fill materials depending on the intended purpose. Cocker-Weber Brush Company has been in business for more than a century, and we are a leading manufacturer of tufted industrial brushes. Our headquarters and production facilities are located in Pennsylvania, but we serve a global clientele. Please contact us to request request more information about our expansive line of cylinder brushes