Surface conditioning products – aka abrasives – are part of an ever-expanding category of non-woven abrasives. Several market trends are influencing suppliers’ new or improved offerings.

GEMTEX TARGETS ERGONOMICS, QUALITY, PRICE DEMANDS

One of those trends is OSHA’s scrutiny of the ergonomic long-range effects that vibration and noise have on operators using type 27 grinding wheels, says Frank Prenda, vice president of sales and marketing at Gemtex Abrasives. “To address this, Gemtex has expanded our emphasis on educating the end user on the values of grinding with flap discs as an alternative to grinding wheels to minimize vibration, noise, and emissions during the grinding process,” he said.

Abrasives products, in various shapes and sizes, are used to blend, deburr, grain and polish metals when specific surface finishes are required. Due to the diversity of this category and range of requests from customers, Gemtex has added three new grades to expand its Brite-Prep surface finishing line and help reduce the need to use coated abrasive products, which could possibly scratch or damage metal surfaces. Extra Coarse, Extra Coarse High Density and Medium High Density have been added to provide longer life, a more aggressive cut and more rigidity within the surface conditioning category. In addition to the seven grades, Gemtex also provides five mounting options (hook and loop no hole, hook and loop with center hole, type R roll-on, and type S screw-on and Spinlock) with 5/8- to 11-inch mount for quick disc changes without the need for a locking washer.

Gemtex offers a ceramic FlapTec, a zirconia GemFLEX and a ceramic/zirconia alternating flap design.

The abrasives market is also driven by end users’ wide-ranging requirements for quality and price. Prenda says many factors, such as working environment, operator skill level, available tools, application and metal types, play a pivotal role in determining the proper disc to recommend for a particular project.

“Some end users require the highest quality product available due to a pre-established finish or specification requirement,” Prenda said. “Conversely, other customers’ needs are satisfied with products that achieve the grinding objectives set forth, while meeting a determined price threshold. It is the job of the abrasive salesperson to recognize the end user’s key requirements and to recommend products that meet their demands while offering multiple grade and mounting options with their flap disc line.”

To meet these demands, Gemtex has introduced an expanded offering of flap discs to address both ends of the quality and price spectrum. The product line, manufactured in the company’s Toronto factory, comprises two brands designated by price and quality. The Flaptec line is manufactured with premium zirconia and ceramic cloth available in fiberglass or plastic trimmable backing. The line also includes a ceramic/zirconia alternating flap design which provides a quality level and price point that fits between their 100% zirconia and 100% ceramic flap disc.

PFERD RESPONDS TO GROWTH OF AUTOMATION

Automation is currently shaping the direction of new product development, according to Jeremy McKinney, senior director of sales at PFERD Inc. “As technology gets better – and as skilled labor becomes tougher to find – more manufacturers are bringing in robots and automated systems to handle grinding, milling, and finishing work,” he said. “Because of that shift, products need to be smarter, more durable, and able to perform consistently in automated settings. But at the same time, we still need to support companies that rely on manual work, so flexibility continues to be a major priority.”

McKinney says PFERD Tools always starts with its customers and partners in mind. “We know that many of them are investing in automation, while others still rely heavily on skilled operators using handheld power tools,” he said. “Because of this, we’re preparing to launch a series of new products in 2026 that support both worlds.”

That will include solutions built for CNC and robotic platforms – where consistency and uptime are key – as well as ergonomic, operator-friendly products. “We want customers to feel confident no matter how they’re working,” McKinney said.

The PFERD RCK drive system can be operated with a power supply unit or with a battery for mobile use.

“In 2026, we’ll be expanding our Solid Carbide Tools portfolio with new end mills and drills for robotic and CNC machining,” he continued. “We’re also introducing tungsten carbide burs designed specifically for robotic applications that combine multiple standard bur shapes into one shape, allowing for programming multiple steps with one bur.”

He asserts these tools are built for accuracy, durability, and high productivity, giving manufacturers more performance with fewer tool changes.

“We’re especially excited about the new RCK drive system,” McKinney said. “It was designed with real-world users in mind, offering the option to run on a battery for mobile jobs or plug in when you’re working at a dedicated station. And because you can adjust the RPMs to match the application, operators get better performance, extended consumable life, and a more comfortable experience overall. Less noise, less vibration, more productivity – however and wherever you’re working.”

WEILER FOCUSES ON THE POWER OF OPERATIONAL EFFICIENCY

Michael Zulauf, product research and development engineer at Weiler Abrasives Group, points to a major focus within the abrasives market today: “Assisting our customers with achieving high efficiency and minimizing costs while maintaining critical product quality.

“Higher performance products may come at a higher cost,” he added, “but it is becoming increasingly evident to supply chains and operators that the resulting gains in operational efficiency, user safety, and product life frequently outweigh the consumable cost and will translate into lower labor and operating costs.”

He believes customers are also looking for partners that do more than just sell them products. “They are looking for partners that provide a comprehensive value package that includes application support, tailored solutions, efficient on-time supply chains and continuous improvement.

QR codes on Weiler products inform users of safety information.

“Safety standards always need to be top of mind when it comes to designing and operating an abrasive tool,” Zulauf continued. “In addition to proper personal protective equipment, the product itself must achieve specific targets with respect to factors of safety for operational speed, attack angle and torque, as well as clear markings that communicate these requirements to the end user.”

The company has developed several programs that support the trends prevalent in the abrasives market today. Zulauf cited the following examples: WCP – Weiler Consumable Productivity: Head-to-head onsite testing versus the incumbent product. SPOT – This safety training program (Speed & Size, Pressure, Orientation, Time) is designed to educate abrasive users on how to use abrasives safely and effectively. Application Engineers – Weiler has traveling experts that can come to the customer’s facility, investigate production problems or product inefficiencies, then recommend or design a standard or custom solution. NPD Stage/Gate Process – This is the Weiler process for launching successful competitive products.

These new products have emerged from Weiler: (1) Tiger 3D MAX Shaped Grain Coated Abrasives; (2) Tiger Mill Scale Wheels; (3) Tiger Strip Non-Woven Cleaning and Stripping Discs; and (4) Tiger Thin Wheel 2.0. Color-Coded Stainless Steel Wire Power Brush Expansion.

BUFFALO IS LISTENING
One of the most expensive components of manufacturing is not the abrasives being used but the labor, according to Kimberly Pigeon, sales and marketing manager at Buffalo Abrasives Inc. “We are always working to develop different bonds and compositions to focus on one wheel that can accomplish what used to require two setups, such as combination wheels.”

Buffalo Abrasives

Responding well to customer demands requires one basic skill for both suppliers and distributors, but it’s often overlooked, Pigeon said: “Listening to what is needed and putting the right technical people behind the efforts to accomplish [the task] or to realistically outline the limitations.”

A major industry trend and hence a focus at Buffalo Abrasives is the increasingly higher speeds of new grinding machines compared to their old counterparts. As a result, Pigeon notes they are very recently placing heavy focus on high-speed bonds for safety.

Share This!

INDUSTRIAL SUPPLY MAGAZINE

The January/February issue of Industrial Supply magazine features an in-depth cover story about Grainger. Plus, we're featuring articles by contributing writers Dr. Bharani Nagarathnam and Frank Hurtte, as well as interviews with numerous product and distribution industry experts.