EBAA Iron Case Story - DISA 240 and DISAMATIC 2070-B
The most cost-efficient way there is of making iron castings
DISA 240 and DISAMATIC 2070-B moulding machines prove their worth at EBAA Iron Inc. in Eastland and Albany, Texas, at cutting the cost per casting to the bare bone.
EBAA Iron manufactures pipe joint restraints for mechanical joints including its own patented MEGALUG joint restraint, flange adapters and push-on joints for fittings, pipes and accessories. The company has a tradition of producing the highest calibre of products through its commitment to quality control and the use of new technology and methods. And it also has a tradition of producing high-quality castings at the lowest possible cost.
“We have been using moulding machines from DISA for many years now,” says Earl Bradley, EBAA Iron President. “Over the years, DISA has earned a lot of respect at EBAA Iron, not least because DISA machines are the cheapest machines to operate, and because of DISA’s commitment and high level of service.”
Huge speed increase
With the most modern ductile iron casting facility in the United States, EBAA Iron depends on DISA to help them keep their costs down and their production moving at a profitable pace.
“When we bought the DISAMATIC® 2110 in 1994, we went from a 2-minute cycle to a 13-second cycle with the same quality,” Earl Bradley continues. “The DISAMATIC replaced a shell moulding operation so the DISAMATIC 2110 was a tremendous boost to our productivity.”
Higher productivity, lower cost per casting
As EBAA Iron grew, the company added a DISAMATIC 2070-B at their Albany foundry in 1996 with a larger 800x950 mm mould size enabling faster production of MEGALUG joint restraints with sharply reduced finishing costs. This was followed in 1999 by another DISAMATIC 2070 MK2-B at the Eastland foundry.
“By 2003 we were running short of capacity so our DISAMATIC 2070 MK2-B at the Eastland foundry was joined by a DISA 240-D, bringing our total up to three DISA moulding machines,” Earl Bradley explains.
EBAA Iron later added a DISA-supplied Robotic Core Setting Unit for the DISA 240-D to maximize the production speed to 400 moulds per hour. “The robot has now eliminated the cycle time delay created by the operator due to setting multiple numbers of small cores into the core mask in each production cycle thereby optimizing our output”, Earl Bradley explains.
“What it all boils down to is that we are now making moulds at least 3 times as fast as before, but with the same number of people. It’s the cheapest way of making iron castings that I know of!”
Efficient core-making keeps costs down
Other DISA equipment at EBAA also includes four CombiCore machines at the Eastland foundry and two at the Albany plant. The CombiCore machines operate independently from the moulding line to produce a sufficient buffer inventory of cores to meet daily production demands and avoid stoppages.
Commitment and support
Correct maintenance that keeps unscheduled downtime to a minimum and yield at a maximum also plays a critical role in keeping down the cost per casting.
“DISAMATIC service and support is second to none,” Earl Bradley continues. “They just want to see us succeed! Those guys know their equipment inside and out and they have access to the parts that keep them running. They have come down here and put on classes at our plant to train our maintenance people how to properly maintain the machine. “
Higher earnings
Earl Bradley is convinced that DISA moulding machines deliver the lowest cost per casting in the world.
“I am certain that our DISA machines make us more money than any other method of moulding. They are so far more efficient that there is really no comparison,” he concludes.
Founded on mutual trust and understanding, EBAA Iron’s relationship with DISA has grown over the decades. Today, DISA is an active partner in the everyday business of EBAA Iron, lowering their cost per casting and keeping their business running strong and enabling them to live up to their motto: “Make it Right, Make it On Time, and Deliver”.