Based in Skoczów and part of the global Teksid iron casting group, the Polish foundry casts over 50,000 tons of iron annually for the automotive sector. Teksid had produced over 28 million moulds on its 40-year-old DISAMATIC 2130 and was still happy with its speed and quality, as well as DISA’s service support.

But although DISA is famous for supporting legacy machines and still supplies most 2130 spare parts, replacement PLCs and other upgrades, some components were becoming hard to find. That risked serious downtime and supply chain problems for Teksid’s clients.

“As well as the high cost of downtime, the new castings we were about to produce required very reliable production,” says Dawid. “We simply couldn’t afford to stop production for days or weeks – we needed to know our production line would keep running.”

Teksid decided to install a new DISAMATIC D5 moulding line. Based on the revolutionary D3 platform, the D5’s multiple innovations and cutting-edge technology deliver the fastest throughputs and maximum uptime for large castings. With three speeds up to 450 uncored moulds per hour, it combines premium mould quality with breathtaking speed, short-run flexibility and minimum maintenance.

“We felt in very safe hands throughout the project,” says Damian Umiastowski, Technology and Process Manager at Teksid Iron Poland. “We had one point of contact and DISA’s careful project planning and experienced team coordination made it very simple and easy for us.”

DISA trained Teksid’s staff on the D5 during installation, with further hands-on training as production ramped up. “The training was great,” says Damian. “Even though we had a DISAMATIC before, it really helped us understand how to use all our machine’s new features. It’s delivered in a practical onsite classroom format which our people liked a lot. We will do more in future for sure.”

DISA has also been very satisfied with the collaboration with Teksid:

“Working with our foundry customer, Teksid, on the new moulding machine was smooth and efficient.
Their clear requirements and quick feedback helped us plan and execute the installation without delays.
We tackled issues together as they came up, keeping downtime to a minimum and ensuring the machine was up and running on schedule. Regular check-ins and open communication made the process straightforward and effective.
In the end, we delivered a solution that met their needs and set a great example for future projects,” says Ole Rossen, Project Manager, DISA.
A third of Teksid’s production is already on the D5 which produces hundreds of thousands of moulds monthly, operating across three shifts, six days a week, yet the line still has capacity to spare.

“Our scrap rate with the new DISA has dropped well below 2% now,” says Dawid. “Its excellent quality means many castings require no fettling at all. The D5 requires very little maintenance and troubleshooting is fast. If there is an issue, the intuitive operator interface tells us exactly what is wrong and how to fix it.”

Support has impressed Teksid so far, both from DISA directly and through DISA’s Total Optimisation Production Services (TOPS) program. TOPS is an exclusive equipment inspection, service and maintenance program for owners of DISA moulding equipment that helps maintain peak machine performance.

“The TOPS inspection visits give us a very structured onsite equipment inspection and adjustment check, plus a report with clear overview of the machine and its condition,” says Dawid. “We will definitely continue with TOPS (Services and Maintenance - DISA Group) and the 24/7 hotline is there if we ever need urgent technical support. From installation to production, the D5 has been rock solid and DISA has done a fantastic job.”