Based in Końskie, Poland, family-owned Fansuld supplies grey and ductile iron castings to a wide range of industries. The leading-edge foundry has extensive in-house capabilities, including sand and quality control labs, many CNC machines and CADCAM design stations.

With 65% of its castings produced and machined completely in-house, and its existing horizontal line fully booked, Fansuld wanted even more flexibility and to open up new markets. More production capacity was needed.

“Our ambition was to have a world-class modern foundry,” says Janusz Postula, co-owner of Fansuld. “Our first thought was DISA vertical moulding and, after visiting a few DISA customers, a DISAMATIC D3 was clearly the best choice.”

DISA supplied Fansuld with a state-of-the-art Complete Foundry, from the entire sand plant through to Wheelabrator shot blast technology. This complete solution saved Fansuld a lot of money, time and anxiety.

“We wanted a single supplier and contract, and DISA made it very convenient,” says Janusz. “DISA solved any small problems during installation, and we were very happy with how they managed the entire project. Having just one supplier for a large project like this is a great advantage and it made it much easier for us to manage.”

Installed in 2023, Fansuld’s D3 can produce up to 425 moulds per hour for castings up to 24kg. The foundry now runs 40% of its annual tonnage on the D3 and is increasing that workload to take advantage of its speed and flexibility.

“We know that our cost per casting will be lower if we can produce it on the DISAMATIC D3,” explains Rafat. “The D3 lets us quote new castings we couldn’t produce efficiently before, which enables us to enter new markets. As a jobbing foundry, we change patterns 3-4 times every shift and the D3 has really cut our downtime for that.”

The DISAMIX delivers consistently good sand quality with the properties we need for our production. “Combining the DISAMIX and the DISA Sand Moisture Controller (SMC) means we have very stable moisture level and other sand properties, even when we stop, start or change the production,” says Rafat.

Fansuld reports its DISA equipment is very reliable and performs exactly as expected, requiring much less maintenance and energy than its horizontal line (from another vendor). DISA’s Total Optimisation Production Services (TOPS) program—an equipment inspection, service and maintenance program for DISA owners—and Fansuld’s use of DISA genuine spare parts will ensure this track record continues.

“We have zero complaints, only positive feedback from the entire operations and maintenance team,” says Janusz. “TOPS onsite visits help maintain peak machine performance and our maintenance team learned a lot by observing the DISA service engineer. We only use original DISA spare parts because we know they will fit our machine, last longer and protect our production.”

Two years after installation, Fansuld is delighted with its investment in its productive, dependable Complete Foundry line.

“DISA has helped us extend our market reach, allowing us to produce new types of castings and compete in new markets, which is a huge gain for us,” says Janusz. “Compared to non-DISA machines, we can produce castings at lower cost. This line is the biggest investment of our lives, so having a trusted partner is very important. DISA is that partner.”