Thorough homework convinced Lee Brass that a DISAMATIC molding machine was the best solution. But after a smooth installation, it was regular service together with superior DISA vertical molding technology that ensured a constantly top-tuned molding line and an ROI inside three years.
Lee Brass owns more than 130 DISA 2110 Patterns ROI within three years.
A DISAMATIC® 2110 Mk3, located in the foothills of the Smoky Mountains in Anniston, Alabama, produces 24 half-inch drop ear ell castings every 12.84 seconds. The pouring time is 7.2 seconds.
Lee Brass, although not the largest producer of brass in the United States, claims to be the best in the business. Plumbing suppliers throughout the United States rely on the quality and the fact that each fitting is pressure tested before it leaves the factory.
Part of Amcast
From its modest beginnings producing a single product 85 years ago, Lee Brass has grown into one of the largest brass foundries in the world. 428,000 square feet under roof situated on 144 acres. They claim to be the only brass foundry that has an on-site smelter to melt its own ingots.
Amcast, a name synonymous with product development and world class manufacturing techniques, purchased Lee Brass in April 1998. Amcast’s copper plumbing fittings, specialty valves, and related controls reach a wide range of industries through a worldwide distribution network.
ROI within three years
The Lee Brass DISAMATIC 2110 Mk3 RH installation includes a Core Setter, and a 15 meter Automatic Mold Conveyor (AMC). “Before installing the DISAMATIC 2110 in 1999, we visited several other brass foundries around the world,” says Foundry Manager, David Smith. “We did our homework because it was a monumental change for us to switch to the vertical process. It was not without some struggles in the beginning, but we’re glad we did. We needed an ROI within three years and the DISAMATIC® was the only machine that could compete on payback. nvironmentally it is easier to capture smoke from the vertical molds because it is a much smaller area than the horizontal line.”
Regular service means optimum yield
Frank Brickhouse, who was responsible for the installation and startup says, “Everything went real smooth. We went right from the shipping skid to the foundation. Once the sand was conditioned, we immediately started pouring metal. And,” he exclaims, “we sold the first casting poured. We buy all our parts from DISA. Last year we rebuilt the AMC. We also have a maintenance contract with DISA. Their service engineers visit four times per year. This keeps the machine in top operating condition. Any additional visits are at a reduced rate because of the service contract. It’s a win-win situation.”
David concludes by saying, “We think we’re the best in the business when it comes to brass and we owe a large part of that success to DISA.”
LEE BRASS
Alabama
DISA Industries A/S
Herlev Hovedgade 17
DK-2730 Herlev
Denmark