DISAMATIC D3 with MOC: Improving Uptime Needn’t Be Rocket Science

Published

The Melt Overflow Cover (MOC), proves that innovations don’t have to be rocket science to make a difference.

We’re often told that over-pours and leakages are just a fact of life in foundries. So we’ve made it our mission to find a solution.

Lars Hjelm, Global Product Manager

Designed and developed to protect the AMC’s mechanical and electrical parts from molten metal, the MOC is a simple yet effective feature that helps increase the reliability of your moulding equipment, optimise your daily foundry operations and improve your overall casting quality - simply by preventing over-pours and overflows. The MOC panels are adjusted to secure a minimum gap between the top rail and the top of the moulds. This creates a barrier against the sides of the mould string, which – in case of overpouring – will stop the excess molten metal and keep it on the mould top. 

The overall aim is to prevent melting overflow and extended downtime, putting a stop to excessive cleaning and maintenance costs, while countering the risk of mismatch due to the Automatic Mould Conveyor (AMC) thrust bar malfunctioning.

“Not a drop of liquid iron on the thrust bars!”

Our Global Product Manager Lars Hjelm explains: “We’re often told that over-pours and leakages are just a fact of life in foundries. So we’ve made it our mission to find a solution. With MOC, we’ve adapted our systems to not only handle, but to directly counteract this daily reality of spills and leakages. Only a few days into its release, the MOC is already proving to be a very popular feature.”

After the first MOC installations at various customer sites, the simple feature and its effect on operations have been hailed by technical staff and foundry managers alike, with one customer describing the improved foundry environment particularly succinctly: “There’s not a drop of liquid iron on the thrust bars!”

Simple technology, astonishing knock-on effects

By protecting all AMC parts, such as thrust bars, heating system and pneumatic systems, from being directly affected by liquid iron, the MOC has a profound effect on foundry operations:

  • fewer stops in production, increasing the number of moulds produced;
  • reduced risk of mismatch (by preventing the thrust bars from malfunctioning due to melting overflow), thereby ensuring maximum accuracy and casting quality;
  • minimised cleaning and maintenance cost (the MOC itself requires very little maintenance and reduces wear and tear on AMC parts).

Lars concludes: “The MOC is an excellent example of how even very simple things can cause a massive change for the better. It’s a feature that has an instant positive impact on foundry operations and outcomes. I’d even go as far as calling the MOC a game-changer in the sense that it optimises equipment reliability significantly, increases uptime considerably, and boosts overall foundry earnings measurably.”

The MOC is introduced to the market as a standard feature on the DISAMATIC D3 AMC. However, retrofit solutions is made available for foundries with DISA lines 130, 131, 230 and 231.