| Output | 40-50 t/month (480-600 t/year) |
|---|---|
| Process | V-process, vacuum sealed molding |
| Metals | iron, steel, non-ferrous alloys |
| Flask sizes | up to 1000x1000x800 mm |
| Molding | mechanized molding line and molding carousel |
| Melting | 500 kg thyristor induction furnace plus resistance furnace |
| Cores | in-house core shop |
| Casting cleaning | tumbling barrel, overhead dead-end shot blasting machine, chamber electric furnace |
| Quality control | metal analysis laboratory, viscometer |
| Floor area | from 400 m2 |
| Includes | foundry cell, machining, painting and quality control |
What this configuration gives you
A complete production cycle. From pattern making to the finished part: molding, melting, pouring, cleaning, machining, painting and quality control.
Binder-free molding. The film transfers the pattern geometry onto dry sand and the mold is held by vacuum. The cost of resins and catalysts disappears, and the sand is easily reclaimed and reused.
Consistent casting quality. With no flash and no parting line, the geometry is accurate and the surface is clean, which means smaller allowances and less machining.
Automation and lower payroll. The mechanized molding line and the carousel take over most of the manual work.
Installed V-process cells
We have commissioned V-process cells with flasks of 1000x600, 1400x1000, 2200x2200 and 2800x2800 mm, from compact shops to large-format casting.
Who it suits
- Engineering, construction and agricultural machinery manufacturers.
- Plants that need thin-walled or large castings with a clean surface.
- Producers for whom savings on molding materials and sand reclamation matter.
What is included
- Mechanized molding line
- Molding carousel
- 500 kg thyristor induction furnace
- Resistance furnace
- Core shop
- Wood milling machine
- Casting ladle
- Tumbling barrel
- Overhead dead-end shot blasting machine
- Bogie-hearth chamber electric furnace
- Laboratory unit for chemical analysis of heats
- Filter unit
- Viscometer
- Foundry hand tools
- Personal protective equipment (PPE)
How the plant works
- Make the patterns from the customer's drawings
- Draw a heated film over the pattern and set the flask
- Fill with dry sand and hold the mold with vacuum
- Pour the molten metal
- Clean, machine, paint and inspect
- Prepare the parts for installation or shipment
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
Why is the V-process cheaper to run than green sand molding?
In the V-process the sand is held by vacuum and needs no binder. That removes the cost of resins and catalysts, simplifies sand reclamation and gives an exact impression of the pattern with no flash.
What casting sizes does the standard package cover?
Flasks up to 1000x1000x800 mm. Installed V-process cells also run larger flasks - 1400x1000, 2200x2200 and 2800x2800 mm - and those projects are quoted separately.
Can the plant make cores?
Yes, an in-house core shop is part of the package; it is what makes castings with internal cavities possible.
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.