TWO OLD TIMERS
New technology together with superior spare parts and service enable Lodge Manufacturing Co. to consistently achieve up to 500 molds an hour with world class castings quality that meets the stringent “no grind” requirements of the foundry.
Lodge Manufacturing Co., located on the banks of the Tennessee River is America’s oldest family-owned cookware manufacturer. Joseph Lodge started the foundry in 1896 and today the commitment to people, quality and product innovation is the same as ever in the capable hands of the fourth generation of the Lodge family.
Advertisement courtesy of Modern Casting Magazine, a publication of the American Foundry Society
First DISAMATIC® in the USA
Lodge Manufacturing also had the first operational DISAMATIC® machine in the United States. “Pleased with the installation!” says Mr. Leslie Kellerman in the December 1965 Modern Castings ad published just after the DISAMATIC was installed. From the first DISAMATIC® in 1965 operating at 240 molds per hour, the Lodge operation grew to five DISA lines in 1987 with two 2011 MK1 and three 2013 MK1 machines. The volume of cookware produced by Lodge on the DISAMATICs continued to increase into the mid 90s. When it came time to upgrade, Lodge again turned to DISA. “And the next generation of the Lodge family was just as pleased with the delivery and installation,” remarks Henry Lodge, great grandson of the founder, and current Lodge President.
Quality, speed and process management
Lodge eventually replaced their five machines with 2 DISA 2013 Mk5-B machines, one with forced mode capable of running at close to 500 uncored molds per hour. “We make over 140 items related to cookware, and we’re making almost as many castings per hour today on two machines than we did on the five older machines. In fact, we’re already planning for the next generation of DISA machines,” says Henry. “The casting finish and the repeatability that we received from our first DISA are still there. But, in addition to the increase in speed, the biggest improve.
Advertisement courtesy of Modern Casting agazine, a publication of the American Foundry Society ment on the newer machines is the communications interface that allows us to collect operational and preventative maintenance data. Plus the operator can scan pattern plate information into the machine to ensure consistency every time we run a job.”
Original parts and service for top quality castings
Parts and service is another area that keeps Lodge coming back to DISA. “We tried parts from competitors”, remarks Jack Plank, Maintenance Manager, “but we had trouble with the tolerances on some parts and had to shim them. We replaced the yokes after purchasing them during the DISA summer shut down sale last year, and then we had someone in the local area re-sleeve them. I was glad to hear that DISA is now offering this service. We always take advantage of the DISA summer shut down sale; this year we’re installing the new design AMC capping strips. We’ve also replaced the chromed rods with the hardened rods from DISA. DISA always has a serviceman here to assist us when we need it and their depth of expertise is consistent no matter whom they send.”
At Lodge, we are committed to a ‘no grind’ program on over 90 percent of our castings and regular visits from DISA under our maintenance contract agreement helps keep the machines in top operating conditions.”
Lodge Manufacturing Co. currently has a Right Hand and Left Hand 2013 Mk-B, both with an 18 meter Automatic Mold Conveyor (AMC) and 10.5 meter Synchronized Belt Conveyor (SBC). Both machines have the Quick Pattern Change (QPC) option; one machine has a Core Setter (CSE); the machine without the CSE is equipped with the forced mode option. CIM Modules 1, 4, 5 and 8 are installed on both machines.
LODGE
DISA Industries A/S
Herlev Hovedgade 17
DK-2730 Herlev
Denmark
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