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DISA Matchplate
Introduced in late 2000 and pioneered by the Benton Foundry in Pennsylvania, the DISA MATCH combines high-quality moulding with a high-speed throughput of 160 moulds per hour (120 with core setting).
The DISA MATCH addresses the urgent needs of jobbing foundries whose customers are demanding smaller, just-in-time deliveries of high-quality castings at competitive prices.
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V-process molding takes advantage of an abundantly available, totally reliable and almost free natural phenomenon to bind molding sand in place... Atmospheric Pressure!
With V-process molding you eliminate many of the costs and problems associated with conventional green sand and no-bake molding.
Because the V-Process uses clean, dry unbonded sand, you can forget about mullers and mixers, and costly sand reclamation and reconditioning equipment. Most V-Process users require only sand cooling and transportation, dust collection and simple screening to remove tramp metals.
Molding equipment is simple too. It can be limited to as few as five items (a vacuum system, Film heater, vibrating table, pattern carrier and flasks) or automated for higher production. There is no need for heavy, noisy jolt squeeze equipment, ramming of slingers.
The molding media is clean and dry therefore shakeout equipment is usually nothing more than a grate to allow the sand to flow away from the casting and back into the sand system. Fume and odor control is unnecessary in most applications.
Low operating cost
You not only save on the cost of sand binders but all of the cost of sand mixing, testing and disposal/ reclamation. Even pattern life is extended because the sand never touches the pattern and it is never subjected to the rigors of a conventional molding machine. Finally, V-Process produces castings with fewer imperfections and less scrap.
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Sand Mould Castings for Aluminium
> optimum compaction process, secure plant engineering
> excellent sand moulds,surfaces nearly comparable to gravity die castings
> considerably reduced amount of cleaning
> electronic process monitoring
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Jolt Squeeze Moulding Machine
A low cost option for foundries looking for a durable, reliable, simple to operate moulding machine to produce moulds of up to 24" x 20". With the appropriate sand feed and box handling systems capable of producing in excess of 120 complete moulds per hour from a pair of machines. Ideally suited to medium repetition foundries producing general engineering castings.
Special Features:
-Combined Jolt Squeeze
-Accurate Draw
-Low Maintenance
-Operational Roller or Pin Lift Draw
-Operational Safety Guards
-Operation Pneumatic, Electrical or Microprocessor Control
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The new DISA Aluminium Process enables aluminium foundries to leverage the cost savings, process efficiency and flexibility of DISA vertical green sand moulding technology. New features including innovative active filling and automatic casting extraction mean that aluminium foundries can now leverage the speed and cost savings of vertical green sand moulding.
The DISA Green Sand Aluminium process is already proving its worth, for example in the production of components for the automotive industry.
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Jolt Squeeze Moulding Machine
The CZ is the manual alternative to the popular CT3 machine allowing a high degree of operator involvement in the production of high quality jobbing castings.
Special Features:
- Combined Jolt Squeeze
- Accurate Draw
- Low Maintenance
- Operational Roller or Pin Lift Draw
- Operational Safety Guards
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Hydrajolt Noise Controlled Moulding Machine
The smaller version of the Swing Arm-Anvil Jolt + High Pressure Hydraulic Squeeze machine. Ideally suited for Flat plate work, Manhole covers &frames etc. High mould hardness values and uniform density is achieved by limited pre-compaction jolting and a high pressure squeeze via the remote free standing hydraulic power pack. Typical box size of 48" x 30" can be used.
Special Features:
- Noise Controlled Pre Jolt
- No Simultaneous Jolt Squeeze
- Operational Roller on Pin Lift Draw
- High Pressure Hyrdaulic Squeeze
- Low Maintenance
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The DISA moulding system has been developed to set a new standard for foundry equipment. The market demands castings with high quality, competitive price and more and more complex shapes. Based on these requirements we have made a completely new design of the mechanical and hydraulic system, including control of the whole process - this is what we call our New Generation!
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Noise Controlled Jolt Squeeze Moulding Machine
This huge machine standing at over 5 metres high is currently producing moulds of 1830mm x 1375mm for the railway industry and at rates of 25 complete moulds per hour utilising one unit machine and a duplex pattern shuttle.
Special Features:
- Noise Controlled
- Combined Jolt Squeeze
- Accurate Centreline Draw
- Variable Jolt Timers
- Operational Roller on Pin Lift Draw
- Operational Safety Guards
- Operational Pneumatic, Electrical or Microprocessor Control
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Jolt Squeeze, Turnover Draw Moulding Machines
A simultaneous jolt squeeze turn over draw moulding machine supplied with tilting roller head for smooth mould transfer. Options include full peripheral safety guarding, Auto or Manual Controls. Typical applications include deep pocketed work in boxes up to 30" x 30" ideal for Manhole covers and frames.
Special Features:
-Combined Jolt Squeeze
-Turnover Draw
-Tilting Roll-out Head
-Auto/manual Pneumatic Control
-Operational Safety Guards
-Low Maintenance
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During the last years Belloi & Romagnoli has developed, together with the above-mentioned multi-piston technology, also the moulding principle based on air impact + high pressure. This choice has been made in order to make a modern and cost-effective technology available to all foundries, also to smallest ones.
The B&R COMPACT 4 moulding machine was designed for foundries that require high quality moulds at low-medium production rates. This machine will provide better quality and faster production rates than the typical jolt squeeze moulding machine. The machine uses air impact and a hydraulic squeeze to make the mould. The moulding media for this machine is green sand.
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For years, FOUNDRY AUTOMATION srl has been known to be synonymous with impact molding. A few of the advantages, that allow high quality production of castings in lead and aluminum, include: accuracy of geometric shape at high density, optimal use of model surface, high permeability, reduced wear and tear in application, and extreme ease in decoring.
Each "ADIABATIC" molding machine is carefully designed from the smallest detail to satisfy all types of molding requirements. Due to the concepts of flexibility and reliability, many foundries throughout the world choose "ADIABATIC" as their preferred molding method. "ADIABATIC" is a sign of quality.
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> for high-speed moulding plants
> simultaneous filling and compaction
> state-of-the-art compaction process AIRPRESSplus 2000
> reliable electronic control of the production process
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> pattern bolster and pattern in outer position
> different modes of pattern changing
> good sand distribution
> low-cost alternative, expandable to an automatic moulding plant
> state-of-the-art moulding technology AIRPRESSplus 2000
> electronic controls
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Moulding is the operation that allows to give shape to green sand in order to obtain impressions as equal as possible to the pattern.
This is one of the most important functions of the production process and deserves a particular attention both from a technical point of view (selection of the type of moulding) and from the point of view of the customization of the plant.
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FRITZ HANSBERG stands-up among the very leading manufacturers of green sand molding equipment.
More than thirty years of experience in the design and manufacture of green sand molding facilities make the name of FRITZ HANSBERG's one of the most respected in the industry worldwide.
Nearly fifty FRITZ HANSBERG molding lines are currently in production with many world-class foundries in Europe and overseas, producing the widest array of cast iron and aluminum castings, from automobile and commercial vehicle, to general engineering, municipality, and domestic heating.
Based upon a three-phase molding sequence featuring pre-fill, shoot, and squeeze, the HANSBERG Molding System is a consolidated, foundry-proven mold making technology which ensures the production of castings consistently complying with the strictest quality control requirements.
- Excellent dimensional accuracy
- Unmatched surface definition
- Minimum weight variation.
Each of the phases of the molding sequence contributes to the production of top quality molds that reproduce the most intricate patterns, with minimum regard to variation in the characteristics of the sand.
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The "Revolution" range of cold chamber machines manufactured by IDRA is another technical development available for customers to give them the competitive advantage.
Different from the traditional toggle machines, the clamping is individually mounted on the 4 tie bars with hydraulic actuators of reduced oil volume to guarantee the same clamping strength as standard toggle machines.
Advantages:
- Automatic compensation of parallelism
- Automatic compensation of thermal expansion
- Shorter start-up times
- Faster closing and opening speeds
- Longer strokes of moving platen
- Less maintenance due to simple construction and less moving parts.
- Shorter total machine length in comparison to a standard toggle machine.
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Automatic core blowing machine with side-thrust vertical split of the core box, including moulding station, based on the Shell-Moulding process.
It is designed in particular to produce cores such as pump impellers and ventilated brake discs.
The machine is equipped with a round spray reservoir and blowing head cooling system.
The pneumatically-powered automatic loading system also includes a loading hopper.
The mobile support, attached to the half-box containing the core, is equipped with a device to overturn it onto the belt using cylinder-driven extractors. Heating is generated by an independent burner frame for each half-box, fed by an air and gas mix (LPG or NATURAL GAS) with heat regulation.
The machine is equipped with a 24V control panel for manual or automatic operation in a single or continuous cycle.
From the protective booth the operator can access the machine while maintaining the safety level established by CE regulations.
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Teubert Unimat
for processing EPP and EPS
The well proven standard machine in solid steel construction with guide bars
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We have taken the wishes of our customers into account. By using new construction techniques and materials, we have achieved a lower price level for our tiebarless TVZ series, which makes this premium technology even interesting in the EPS business.
The original TVZ design used a hybrid drive system of electric and hydraulic. At the request of our customers, a hydraulic drive system with separate driving and clamping cylinders is now implemented into the TVZ machines.
This is an example of the customer driven design refinements which have lead to both design advantages and cost savings, helping to offset the surcharge of the tiebarless molding technique.
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From the development in 1990 to the leading sun visor supplier of complete machine and tooling systems for sun visor half clam shells.
Teubert delivers customized machines for the production of In-Mould Skinning and foam-backing EPP clam shells.
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The expansion of the product range by special particle foam materials such as Expandable PolyPropylene (EPP), Expandable PolyEthylene (EPE) or copolymers has also considerably improved the options available to the manufacturers of mouldings to open up new sales opportunities by means of new applications. These particle foam materials make special demands on the machine building industry in terms of an increased closing force for the moulds. Kutz shape moulding machines of the HP-line can be operated with a steaming pressure of 5 up to 7.5 bar.
Mouldings made of EPP are especially suited for impact loads because of their mechanical properties. Therefore they are used more and more in the automotive industry for quite a long time now. These parts are featured by a high energy absorption capacity, a wide temperature range, a good ability to restore the original shape as well as by a simultaneously available recycle ability.
Well known applications such as sun visors and bumpers are nowadays supplemented by knee pads or side impact protection systems as they are used to increase the passengers' safety. Kurtz has accompanied this development permanently or was ahead of it having the matching machine concept for every application available.
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The standard product range of shape moulding machines laid out for steam pressures of 1.5 bar comprises steam chamber dimensions of 600 x 800 mm to 1,100 x 2,100 mm. Thus Kurtz can supply economic solutions for most applications.
Machine design is based on a solid closing unit with fixed and moving steam chamber and on 4 tie bars ensuring symmetric closing force by means of hydraulic cylinders situated on both sides.
The portal stand on the driving side provides easy access to the machine interior, shortening set-up times.
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The machines of these types are especially suitable for manufacturing medium to large lot sizes. Performance characteristics of the EHV moulding machines:
Highest corrosion resistance through the robust steel construction with high quality surface lacquering
Optimally dimensioned media piping and all-electronic control systems
Operator-orientated display surface with process-oriented menu configuration
- integrated error message administration
- integrated maintenance schedule
- teleservice-compatible (EM Service)
Machine stroke 1,000 mm (max. 400 mm moulding depth)
- optional stroke variants 1,500 mm (max. 650 mm moulding depth)
- optional stroke variants 2,000 mm (max. 900 mm moulding depth)
Filling system of 30 to 600 l with electronic pressure regulation
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Innovative Rotational Molding Machines:
Turning raw materials into finished products has taken a simple leap forward. Rotoline has engineered a straight forward approach to increase production and decrease cost. Our shuttle machine has the highest productivity and efficieny due to an innovativecircular oven, and heavy duty Arm/Cart design. The Rotoline shuttle machines are unchallenged in productivity, cost, and durability by any other worldwide recognized Rotomolding machine.
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