Big, Vertical and Economical

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Big Vertical and Economical

The fastest way to produce large castings

Large castings such as cylinder blocks and large manhole covers are traditionally produced using horizontal moulding technology, in spite of its larger space and manpower requirements, higher workplace impact, lower speed and higher cost per casting compared with vertical moulding. 
 
Link to New Generation Lines
With the DISA 280-C, DISA proves that quality production of large castings is now both much faster and more economical than traditional horizontal moulding technology.
 

New Generation

DISA has marketed a long line of vertical moulding machines, starting with the DISA 231 that take advantage of its scalable, New Generation technology. The New Generation technology platform features an innovative hydraulic system, fewer moving parts, handling equipment, remote monitoring and diagnostic systems, and many other advanced features.

“It has always been our ambition to develop a vertical moulding machine big enough to produce very large castings such as automotive engine blocks and large manhole covers,” says Niels Winther Rasmussen, General Manager, Foundry Technology at DISA. “The new DISA 280-C with a mould face of 1050 x1200 mm is the culmination of our efforts. This new machine offers a high-speed, high-quality and low workplace impact alternative to horizontal technology for the production of large castings at a significantly lower cost per casting.”

In October/November 2012, DISA held two seminars at its headquarters in Denmark for 80 foundry representatives from 19 different countries making automotive castings and manhole covers. The subject was the production of large castings using vertical moulding technology. The conclusion pointed unmistakeably to a paradigm shift from horizontal to vertical moulding.

Putting it to the test

The seminars in Denmark gave influential customers the opportunity to look back on up to 50 years of vertical greensand moulding, and look ahead to what is set to be the new standard for the production of large automotive castings and manhole covers.

Setting the scene, Yoshidi Akira from the Tochigi foundry of Nissan Motor Company Ltd. in Japan stated that Nissan had been making V6 cylinder blocks on DISA 2070 vertical moulding machines for 30 years. His experience over this period was that the production cost was 85%, the maintenance cost 88%, and energy consumption of as little as 20% of that of a horizontal moulding machine.

Steve Harkness, Product Development Manager at Intercast & Forge in Australia, cited the moulding qualities of its DISA 250-C at its Adelaide foundry as an important competitive advantage. “The moulding qualities of DISA machines are a large part of the technical advantage we have over our competitors. For example, we make a number of different castings on our DISA 250-C for which our customers cannot find other suppliers who can technically make the parts to specification.”

DISA 280-C – the biggest yet

When Payza Dökum in Turkey ordered their first DISA 280-C after a presentation at GIFA 2011, the machine was specifically intended for production of manhole covers, Mr. Abidin Payza, explained during his presentation at the DISA 280-C symposium.

“Our decision was based on the experience and expertise of DISA in moulding technology and large moulding machines as well as the obvious economic advantages offered by the DISA 280-C. These are of lower sand consumption, lower energy requirement, its high speed of 280 cored moulds an hour, high efficiency and precision, easy maintenance and troubleshooting, and easier, faster and cheaper installation.”

Abidin Payza expects the DISA 280-C to add 2000 tons to its monthly production capacity.

A new paradigm

DISA Sales VP Per Ejdorf anticipates a new business paradigm at foundries making large automotive castings and other large components such as manhole covers.

“The fact is that foundries using DISA vertical moulding technology could meet and exceed specifications and that their cost per casting was up to 15% lower. Their experience together with the advanced technology of the DISA 280-C is a clear sign of a new awareness of how DISA vertical moulding technology can be applied to large castings. Big is not only desirable. It is also vertical and economical.”