DISA Matchplate moulding machines

DISA Matchplate moulding machines are for foundries that specialise in the short to medium-run, high-efficiency production of quality castings and  require fast pattern changes for maximum uptime

Patented DISA matchplate technology combined with the unique DISAMATIC® Blow/Squeeze mechanism means it consistently produces high-quality castings at high speeds, with fast pattern change times.

With over 120 machines installed worldwide, the DISA MATCH is a reliable matchplate moulding system for iron, aluminium or other alloys.

DISA MATCHPLATE TECHNOLOGY

Key Benefits

Up to 180 uncored moulds /hour

With machine-related mismatch of max 0.2 mm for minimal finishing costs

Rapid, precise pattern changes

Unbeatable uptime and mould quality

A range that covers your matchplate needs

DISA MATCH 20/24: perfect for jobbing foundries looking to transform casting quality and production efficiency. Its matchplate adaptor makes it easy to upgrade from competitor machines.
DISA MATCH 24/28: highly flexible matchplate casting production for a wide range of applications.
DISA MATCH 28/32: reduce the need for human intervention and step up production of larger, more complex castings
DISA MATCH 32/32: the flagship model’s large mould size is perfect for a broad range of automotive and other applications that require bigger moulds.

Supports that pays

DISA offers worldwide support of the DISA MATCH 20/24, 24/28, 28/32, 32/32 to help maximise foundry performance at all times, thanks to:

  • fast delivery of original spare parts
  • on-site technical support from offices close to you
  • 24-hour support hotline
  • DISA TOPS, DISA's exclusive customer inspection, service and maintenance programme application and training experts on demand

Perfect for jobbing foundries requiring quick plate changes

The DISA MATCH is the most rigid and accurately-controlled green-sand matchplate system available.  With rapid, precise pattern changes and an easy-to-use operator interface, the DISA MATCH enables jobbing foundries to achieve the lowest cost per casting – even for short runs.

  • The DISA MATCH 20/24 machine can reach speeds of up to 180 uncored moulds per hour.
  • It delivers a maximum machine-related mismatch of only 0.2mm (0.25 for the two larger mould-size versions). 
  • Maintenance-friendly design, including easy access to the moulding area, reliable service support and wrap-around preventive maintenance ensure your DISA MATCH moulding line is up and running when you need it.

Quality moulds, lower costs

The DISA MATCH’s rigid design and smooth operation produces premium-quality moulds with

  • maximum machine-related mismatch of between 0.2 and 0.25mm (depending on mould size)
  • DISA in-chamber parting spray system to prevent sand sticking to the pattern plate
  • patented sand slot design for optimum mould quality

These features mean DISA MATCH delivers consistently higher casting quality with less need for machining – keeping finishing costs to a minimum.

 

Deep pockets, perfectly filled

The sand blow system deployed in the DISA MATCH is based on 50 years of experience. It ensures effective sand filling, even of deep-pocket moulds, with no need for ram-up blocks and is easy to clean.

Fully adjustable stripping height and acceleration protect mould integrity and optimise the cycle time, while the adaptable mould height system ensures a constant sand-metal ratio.

 

Easy conversion from manual to automatic

Simple adaptors let you reuse existing jolt squeeze pattern plates or other matchplate patterns in the DISA MATCH machine with only few modifications.*

That makes upgrading from jolt squeeze or other matchplate technologies to DISA MATCH quick and painless. Our experts are ready to help you apply this proven solution.

* Subject to evaluation as some patterns may not be suitable for conversion.

We have several thousand active patterns and we have 1,000 - 1,500 very active patterns, meaning that we make them at least once every couple of months. None of our work is long-run work, and thus part of the DISA package that was so attractive to us was the job change time. It is much, much quicker on this machine than on any other matchplate machine I have been around.

Mike Slaydon, Operations Manager at Rochester Metal Products.

With clever features, it's a match you can count on

Perfect for your process

For maximum output every match machine model combines high speed, fast pattern changes and consistent mould quality with low mismatch.  Fully integrated PLC and hydraulic systems regulate every movement.

Sophisticated adaptive mould thickness control comes as standard, ensuring consistent mould thickness even when sand properties change. Added to the super-rigid machine frames and guide rods, this produces very high casting accuracy and repeatability.  Additional features include:

  • fixed cope for flexible mould changes and extra-precise stripping
  • enhanced pattern carrier design (28/32 and 32/32) 
 

Flexible, clean operation…

DISA MATCH offers fast and simple pattern changes with completely flexible, easily-adjusted Down Sprue positions. 

Operators have increased workspace, with a cleaner and quieter working environment.  Additional benefits include:

  • in-chamber pattern spray reduces parting fluid usage and airborne parting fluid
  • light curtain for easy and safe operation
  • large colour VDU for user-friendly operation and trouble shooting 

Minimum maintenance

DISA MATCH’s robust and simple design uses minimum moving parts, that means less maintenance and unbeatable uptime. Service-friendly access and clever features further reduce maintenance time and cost.  Features include:

  • easy-to-change cope and drag wear plates
  • automatic lubrication system
  • external hydraulic power unit (20/24 and 24/28)
  • patented easy-to-exchange chamber wear plates

Every DISA MATCH is delivered fully tested and installation-ready for fast commissioning. In operation, you can rely on the industry’s best aftermarket parts and service network.

 

Instead of just 16 moulds /hour using the old jolt-squeeze machines, we are now turning out 28/32 moulds at a rate of 75 /hour. The fully automated moulding machine and mould handling line are fully synchronized and our manpower requirement has dropped from 26 to just 6 people.
Our ability to produce more complex castings means we can now offer our customers a much wider range of more complex and heavier components, and our machining costs have been cut right down to the bone.

Tadeusz Jurga, Vice-Chairman Drawski Cast Iron Foundry, Poland

Options that make a difference

DISA Automatic Core Setter (CSE)

The Automatic Core Setter is a simple, reliable design that is fully integrated with the MATCH machine. Available for all DISA MATCH sizes, the CSE is particularly valuable for long production series and for setting heavy cores precisely into the drag mould.

The DISA CSE for DISA MATCH 28/32 and 32/32 gives the operator 36 seconds to place the cores in the core mask. Built-in alignment between the core mask and drag mould aids rapid matchplate changes.


DISA Quick Matchplate Changer (QMC)

The Quick Matchplate Changer enables the precise changing of matchplates within two minutes. 
It is highly recommended for both smaller and larger moulding machines where matchplates can weigh up to 400 kilos (900 pounds).
 

DISA Computer Integrated Manufacturing (CIM)

DISA Computer Integrated Manufacturing enables direct connectivity between the DISA MATCH and reporting applications on the foundry network. 
It facilitates real-time production monitoring, reporting and pattern-related parameter download to the moulding machine. 
 

Automatic mould handling (AMH)

Mould integrity throughout pouring, solidification and cooling is critical in casting production. Automatic mould handling (AMH) ensures steady, controlled transport of poured moulds - for mould integrity end to end.

How is works

DISA’s Automatic Mould Handling system has been designed specifically to work in tandem with the DISA MATCH moulding machine. 

Consisting of a variable-length pouring/cooling line and an automatic weight and jacket transfer cleaning station, the DISA AMH synchronises perfectly with the DISA MATCH to ensure mould integrity all the way to the shakeout. 

After the last mould has been transferred to the shakeout or belt conveyor, the pallet cars pass through a pallet cleaning station, before a new mould is placed on the pallet car again. 


Keeping up with high speeds

The high speed of the DISA MATCH requires a mould handling system that enables effective mould cooling. 

The AMH allows effective cooling on minimum floor space, without having to compromise on moulding speed. This is achieved through up to two parallel conveyor sections installed between the DISA MATCH and the final shakeout. 

Additional cooling can be achieved by adding a belt conveyor before the shakeout. 

Remote troubleshooting

As with DISA MATCH, the DISA AMH also supports the DISA Remote Monitoring System (RMS). This allows a DISA engineer to connect directly to both the DISA MATCH and AMH operator panels to obtain the information necessary to fix problems and maximise performance and availability.