Optimization of abrasive costs

Mistake #1: Choosing based on the price of the disc

Imagine the situation: a buyer sees two 125x1.0 mm cutting wheels. One costs 20 UAH, the other - 40 UAH. Is the choice obvious? No. This is the most common and most expensive mistake in the purchase of abrasive tools.

A disc is a consumable. Its value is not in the price per piece, but in the amount of work it will do. A cheap disc that makes 20 cuts costs more than an expensive disc that makes 60 cuts. It's counterintuitive, but the math is undeniable.

Cutting cost formula

The only metric that matters when purchasing abrasive tools is:

This formula works for any abrasive tool: cutting wheels, grinding wheels, flap discs, fiber discs. Simply replace "number of cuts" with "number of parts machined" or "surface area machined".

For the full picture, also consider:

• Disk replacement time— each replacement = 2-5 minutes of downtime. Fewer replacements = more productive time
• Man-hour cost— if Extreme cuts faster, the worker processes more parts per shift
• Logistics— fewer disks = fewer orders, less warehousing costs

Series comparison: Standard vs Profi vs Extreme

Let's consider real numbers using the example of a 125x1.0 mm cutting wheel (cutting 12 mm rebar):

* Test: 12 mm reinforcement, 125x1.0 mm wheel. Data from NovoAbrasive technical department. Prices are approximate, current prices on request.

Time factor: speed = money

The cost of cutting is only the direct savings on discs. There is also an indirect one, which is often larger:

Cutting speed

Ceramic grain (Extreme) cuts 35% faster than aluminum oxide (Standard). For a company with 5 workers making 200 cuts per day, this means:

• Standard: 200 cuts x 15 seconds = 50 minutes of clean cutting per worker
• Extreme: 200 cuts x 10 seconds = 33 minutes of clean cutting per worker
• Savings: 17 minutes x 5 workers = 85 minutes (1.4 man-hours) per day

For 22 working days, this is 30.8 man-hours per month. At a rate of 150 UAH/hour, this is 4,620 UAH of additional savings, which is not reflected in the price of the disk.

Fewer disc replacements

Each disc change is 2-5 minutes of downtime: stop, cool down, change, start. At 200 cuts per day:

• Standard (20 cuts/disk): 10 changes x 3 min = 30 min downtime
• Extreme (60 cuts/disk): 3-4 replacements x 3 min = 10 min downtime

Correct selection of the series for the task

Optimization doesn't mean "always buy Extreme." Proper selection is about matching the series to the actual volume and operating conditions.

Storage: Investment Protection

Proper storage is not about accuracy, it's about money. A disk that has lost its properties due to improper storage is a 100% loss of investment.

• Temperature: 18-22°C (tolerance 15-25°C). Unheated warehouse in winter = condensation = bond failure
• Humidity: 45-65%. Bakelite bond is hygroscopic - absorbs moisture and loses strength.
• Position: horizontal on a flat surface. Never on an edge - deformation
• Protection: from direct sunlight, chemicals, mechanical shock
• FIFO: First In, First Out — use previously purchased disks first

FEPA expiration dates: Bakelite bond - 3 years, vulcanite bond - 5 years, ceramic bond - 10 years. Expired circles = disposal.

Work technique: +20-30% resource for free

Proper working technique is the cheapest way to optimize. You don't spend a penny, but you get 20-30% more cuts from each disc.

For cutting wheels

• 90° angle to the surface - the cutting wheel only works perpendicularly. Tilt = side load = accelerated wear + danger
• Even feed - don't press. Let the abrasive cut. Excessive pressure overheats the bonds and accelerates grain failure
• Avoid "rocking" - back and forth movement in the cut widens the groove and wears the side surfaces of the wheel
• Proper workpiece clamping - vibration from an unclamped part wears out the wheel and degrades the cut quality

For grinding/polishing wheels

• 15-30° angle to the surface - optimal contact area for effective removal
• Uniform movement - do not stay in one place, move the grinder evenly
• Gradual removal - several light passes are better than one with maximum pressure

Private Label for distributors

For distributors and retail chains, NovoAbrasive offers contract manufacturing under your own brand (Private Label). This is a way to get a European quality product with MPA Hannover certification - under your own brand.

What you get

• Full production cycle - from recipe to packaging. Equipment Davide Maternini (Italy) and ABRAPRESS
• MPA Hannover certification is the only Ukrainian manufacturer with this certification. Your product = our quality
• Your design— label, packaging, colors, logo — everything under your brand
• Flexible specifications— selecting a formulation for your market and tasks
• Minimum order: from 5000 units
• 50+ active Private Label clients in 35+ countries

Raw materials are exclusively European (Austria, Germany). 6-stage quality control: incoming raw material control, mixture control, parameter check, tensile test, lateral load, control cut.

Wholesale terms and partnership

NovoAbrasive offers transparent and favorable conditions for wholesale buyers and distributors:

• Fixed prices per quarter - you can plan your budget without the risk of price jumps
• Personal manager— each client works with a dedicated specialist who knows your specifics
• Technical support— assistance in selecting the optimal product for your customers' tasks
• Marketing support— POS materials, catalogs, technical brochures
• Flexible logistics - warehouse in Ukraine, delivery across Ukraine and for export

Production capacity — 30,000,000+ units per year. We ensure stable supplies even for the largest customers. NovoAbrasive is a member of FEPA since 2017.

Frequently asked questions

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