Lee Brass Alabama Case Story - DISAMATIC 2110 MK3
Thorough homework convinced Lee Brass that a DISAMATIC® molding machine was the best solution. And 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
A DISAMATIC® 2110 MK3, located in the foothills of the Smoky Mountains in Anniston, Alabama, produces 24 half-inch drop ear elbow 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 and Industrial suppliers throughout the United States rely on the quality and the fact that each fitting is pressure tested before it leaves the factory. From its modest beginning producing a single product 87 years ago, Lee Brass has grown into one of the largest brass foundries in the world. 428,000 square feet under roof situated on 138.5 acres. They claim to be the
only brass foundry that has an on-site smelter to melt its own ingots.
Lee Brass is a diversified company participating in the following markets: Plumbing & Industrial PVF, Marine, Commercial OEM and Water Meters. Many of the items that run on the DISA are for use in the U. S. Navy Shipbuilding program that requires a very high standard of quality.
ROI within three years
The Lee Brass DISAMATIC® 2110 MK3 Right Hand installation includes a Core Setter, and a 15 meter Automatic Mold Conveyor (AMC). “Before installing the DISAMATIC® 2110 MK3 in 1999, we visited several other brass foundries around the world,” says Vice President of Operations, 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 a ROI in three years and the DISAMATIC® was the only machine that could compete on payback. Environmentally 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
“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 maintenancecontract 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 winwin 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.”