BCI replaces two competitor matchplate machines with one DISA MATCH
Family-owned and family-run since 1939, BCI Solutions, Inc. supplies high-end, machined gray and ductile iron castings to a global customer base from its foundry in Bremen, Indiana, USA.
Always ready to invest in the latest technology, BCI was looking for a new 20/24 matchplate molding line to replace two older 14/19 machines. It had struggled to source molding line spare parts during Covid, so reliability and strong support were top priorities.
“After years of investing in new machinery, we’ve learned to do our due diligence in depth,” says JB Brown, CEO at BCI Solutions. “Talking to other DISA foundries, we heard again and again that the DISA MATCH is a tank: a strong, high-quality and well-supported machine."
Over 50% faster production
The compact DISA MATCH comes in six chamber sizes, from 14/19 to 32/32, and with speeds up to 210 moulds per hour (mph). Pattern changes take only two or three minutes, with automatic core setting optional.
“Working with DISA was seamless,” says JB. “The machine went in smoothly and the MATCH’s matchplate adaptors let us re-use all our old 14/19 and 20/24 plates on it. The training went great, we powered it up and, voilà, the next thing we knew, we were making moulds.”
Producing more, better quality castings - faster
The rigid and precisely controlled DISA MATCH has already reduced BCI’s overall scrap rate. Casting surface finish is excellent, with parting lines less visible and very little grinding required. Running across two, 10-hour shifts weekdays, the DISA MATCH is now the foundry’s firm favorite amongst the other molding machines it operates.
With tighter parting lines, fewer sand-related defects, and reduced grinding requirements, BCI is improving quality while simplifying operations.
“It makes a nice tight mold that doesn’t need to be blown off, which saves a lot of previously wasted labor time,” says JB. “Of all our machines, it produces the best mold and the best-looking casting -100%. Shift mismatch is almost irrelevant with the MATCH and defects are down too, especially sand-related defects. If you want a quality casting that looks good, produced really fast, then definitely go with a DISA MATCH.”
BCI particularly likes the clean, easy-to-use interface. To get ready for the next run, the operator just punches in the component part number and the MATCH’s Monitizer | CIM recipe manager automatically loads the settings.
Less maintenance, excellent support
So far, the machine has needed far less maintenance than the other in-house machines and has been completely reliable. If there are any questions, DISA’s 24/7 telephone support is always available.
“We have to make constant adjustments on our other matchplate machines, like adjusting slippers every hour,” says JB. “The DISA MATCH doesn’t need any of that. It’s just the way it is engineered and built, they’ve developed a very robust machine. The 24/7 support line is something that no other molding company offers, and we’ve called it a couple of times during nightshifts. My team really appreciates that support.”
BCI is very happy with its new DISA MATCH, and there’s more to come. Working and training with DISA, the foundry is finetuning machine settings and gating for different applications, so it can run even more jobs on it. It is fitting an automatic core setter and is also deploying the Monitizer | DISCOVER IIoT solution foundry-wide to help further reduce waste and maximize efficiency.
“The DISA MATCH is the best molding machine I've ever had, it’s the Ferrari of the molding industry,” says JB. “With DISA you truly get what you pay for. The ROI has been really good, and it is great value for the investment. I would buy another one today - and that’s our plan.”