| Output | up to 100 t/month (1,200 t/year) |
|---|---|
| Processes | lost foam casting (LFC) and V-process |
| Metals | iron, steel |
| Flask size | 1250x1450x800 mm |
| Molding line | mechanized, five 1250x1450x800 mm flasks |
| Melting | 1000 kg thyristor induction furnace assembly plus resistance furnace |
| Pattern shop | three PA-400 semi-automatic machines with pre-expander, bead blowing unit |
| Casting cleaning | tumbling barrel, overhead dead-end shot blasting machine, chamber electric furnace |
| Quality control | metal analysis laboratory, pentane meter, viscometer |
| Floor area | 300-600 m2 |
| Includes | foundry cell, machining, painting and quality control |
What this configuration gives you
Large-format casting. The 1250x1450x800 mm flasks and the 1000 kg furnace are meant for heavy parts that the 50 t/month configuration can no longer handle.
A full cycle. The foundry cell, machining, painting and quality control are all part of the package, so what leaves the plant is a finished part, not a rough casting.
Accuracy and surface finish. Lost foam and V-process molds have no parting line, no cores and no flash, which keeps machining allowances to a minimum.
Payback through volume. 1,200 tonnes a year with minimal molding labor is the core economic argument for this configuration.
Who it suits
- Producers of large housing and frame castings.
- Metallurgical and mining companies with their own repair castings.
- Companies moving from buying castings to producing them at industrial scale.
What is included
- Mechanized molding line with five 1250x1450x800 mm flasks
- 1000 kg thyristor induction furnace assembly
- Resistance furnace
- PA-400 semi-automatic pattern machine with pre-expander (3 units)
- Bead blowing unit
- Drying cabinet
- Dissolver for refractory coating
- Casting ladle
- Foam milling machine
- Hot-wire cutting machine
- Tumbling barrel
- Overhead dead-end shot blasting machine
- Bogie-hearth chamber electric furnace
- Laboratory unit for chemical analysis of heats
- Pentane meter
- Filter unit
- Viscometer
- Foundry hand tools
- Personal protective equipment (PPE)
How the plant works
- Make foam or wax patterns
- Set the patterns into the large 1250x1450x800 mm flasks
- Pour the melt and hold the slow-solidifying castings in the mold
- Take out accurate shaped parts
- Machine, paint and inspect
What the delivery includes
- Process training: from raw material preparation and molding through to finishing, in theory and in practice.
- Machine training: settings, operating modes and maintenance of the CNC and auxiliary equipment.
- Staff training for process engineers, CNC operators, quality inspectors and foundry workers.
- 12-month equipment warranty, including free repair of any faults.
- Process support at start-up: inspection of every unit and set-up of the production flow.
- Ramp-up to the rated output, with checks on casting and machining quality.
- Handover to full autonomy: process instructions and contacts of vetted material suppliers.
- Supervised installation: assembly, commissioning and a test run on your site.
- Ongoing technical support after production starts.
Delivery is quoted separately depending on the destination.
Frequently asked questions
How large can the castings be?
The envelope is set by the 1250x1450x800 mm flask, which is enough for large housing and frame parts that do not fit into 700x700x800 mm flasks.
How much metal does one heat give?
The thyristor induction furnace assembly is rated at 1000 kg, twice the 500 kg furnace of the 50 t/month configuration.
Does a 100 t/month plant need a dedicated building?
No. The layout is designed for 300-600 m2, including the foundry cell, machining, painting and quality control.
Request a quote
Send us a drawing or a photo of the part. We will work out the process, the plant configuration and the price.