Moulding

MOULDING DEPARTMENT

Moulding machine technology has come a long way in the last 10 to 15 years, especially for foundries like us who make a wide variety of castings in shorter runs. We had been happy with our old moulding machine, but were now looking for a more ambitious solution that would address several important issues at once.

ENVIRONMENTAL ASPECTS

The environmental aspect was an important one for the Asia Steels. Noise and dust always make it difficult to reconcile an iron foundry with urban surroundings, and the foundry’s two Hunter moulding machines lacked the technology to meet modern environmental standards.

IN CHAMBER SPRAY

Our quality policy dictates the use of modern technology and the credentials of the DISA MATCH made it impossible to ignore. The first thing you notice about the DISA MATCH is the compact and attractive design with a hidden promise of advanced technology. One of the major advantages for us in this respect was the closed system with the spray inside the moulding chamber. This contrasted with the open spray of the Hunter, helping to make a very significant improvement to the working climate.

HIGHER SPEED AND PRECISION CORE SETTING

One striking difference between the DISA MATCH and the replaced moulding machine is speed with the DISA MATCH performing at a constant 150 moulds per hour without cores, against just 80 from the other machine.

Another speed-related issue was core setting. One of the reasons for going with the DISA MATCH was the automatic core setter which ensured precision core setting and enabled us to maintain a constant 120 cored moulds an hour.

FLEXIBILITY & LOWER COST

Speed is not everything however. The DISA MATCH can produce a wider range of castings with the Quick Match plate Change Unit enabling rapid changeover between runs. The lack of mismatch of the DISA MATCH means a significantly reduced finishing requirement leading to savings in production costs. Another area in which the DISA MATCH has delivered significant cost savings is in metal usage.

SUPERIOR QUALITY & LOWER COST

Several months after the DISA MATCH came on line, Asia Steels staff and operators can stand beside the new machine and savour the low noise level and clean working environment. We are getting the output and castings quality we were promised. Both are far superior to what we were used to on the old machine. And on top of that we are realising considerable savings in finishing and metal costs, our customers are happy and so are our employees and immediate surroundings

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