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1 Buy factory direct
If you buy $3000 at a time of any one model of buffing wheel, it will be more economical to buy factory direct - even across the world from India. You save on the costs of the middle men - importer, wholesaler,retailer, etc etc...
2 Use unbleached grey fabric buffing wheels
Off white, unbleached loomstate cotton fabric wheels give exactly the same performance as bleached fabric wheels. Bleached (white) cotton fabric is visually attractive, but does not contribute anything to the performance, only jacking up the expense.
3 Use wheels made from special fabric
It is a false economy to use remnants or cuttings from apparel fabric for buffing wheels.
Apparel fabric is loosely woven, and buffing wheels made from loosely woven fabric fray easily with the result that the wheel has no endurance.
Fabrics specially designed for buffing are extremely closely and tightly woven on modern state of the art looms. Such fabric does not fray easily giving a better performance and a higher endurance.

Apparel fabric

Special fabric

Frays easily along the length and width

Stitched bias cut lengths

 4 Use two step buffing
The yarn pulls out easily (the fabric frays easily) along the length (weft) and along the width (warp). But if the fabric is cut diagonally (bias cut) the yarn does not pull out or fray easily. Bias cut wheels are made by cutting the fabric diagonally, stitching the fabric lengthwise, and fixing the fabric on a metal wheel.
The endurance of a bias cut metal center wheel is at least 10 times that of a straight cut wheel sewn at the center.

Step 1

Rough finishing wheel made from stitched cut lengths

Step 2

Final finishing wheel

 Step 1 : Use a bias cut metal center wheel for rough finishing.
Step 2 : Use a straight cut center stitched wheel for final finishing.
5 Save labor
Use 2, 3 or 4 buffing wheels mounted with washers on the buffing wheel arbor. The job will be done in 1/2, 1/3 or 1/4 of the time.
If the present motor is underpowered use a more powerful motor and a more rugged drive.

6 Use jumbo wheels
The overhead and labor for manufacturing a larger diameter (jumbo) wheel is the same as the smaller wheel. Jumbo wheels are therefore always more economical.
Jumbo wheels ( 18” or 20” + wheels) need bigger shrouds and slower running arbors (variable speed motors).
But buffing wheels are a recurring expense whereas buffing machines are a one time expense.
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