Consistency at 200+molds per hour
“Today we’re running a no-cored job at 213 moulds an hour, which is just unheard of for a matchplate machine.”
Founded in 1916, Progressive Foundry in Perry, Iowa (USA) has more than a century of experience adapting to change. In the last seven years alone, the foundry has installed three DISA moulding machines - an investment driven by the need to maximize output during their single-shift operation.
“We run a one-shift operation, so we try to get the most we can out of one shift - and DISA has helped us do that”
- says Darek Vankirk, President of Progressive Foundry explains.
Since installing its first DISA MATCH in 2018, Progressive Foundry has seen steady and measurable performance gains. What began at roughly 150 moulds per hour (cored) has evolved into consistently higher speeds following the speed upgrade kit.
“Very consistently we see 170 moulds per hour on a cored job,” Josh Magill, Plant Manager notes. “Today we’re running a no-cored job at 213 moulds an hour, which is just unheard of for a matchplate machine.” Beyond speed, consistency has been a game-changer. DISA MATCH delivers harder molds, tighter parting lines, and predictable performance - regardless of job complexity. “Production consistency makes scheduling easy,” Josh continues, “if it’s got 30 cores or 10 cores, it’s going to run at 170 molds an hour all day long. There is minimal downtime and changeovers are quick.”
A standout feature for Progressive Foundry is the automatic core setter, which has significantly improved both quality and operator experience. “My favorite aspect of the DISA MATCH is the core setter - hands down,” Darek shares. “It’s made our life better here at Progressive Foundry.”
“The automatic core setter is one of the best features of the DISA MATCH machine,” says Nate Magill, Maintenance Supervisor. “It installs the cores more precisely than a person can by hand. It really makes a difference in mold quality.”
Just as important as machine performance is partnership. Progressive Foundry credits DISA with listening, innovating, and continuously improving the equipment based on real-world foundry needs.
“It’s evident DISA understands the foundry environment,” Josh says. “They listen to their customers and continuously make their equipment better. The latest machine we bought has quite a few upgrades.” “We’d recommend the DISA MATCH to any foundry. The DISA MATCH core setter is really hands down, better than anything else on the market” Josh notes, “Operators love them, we love them.”
That collaboration - from design through service - has allowed Progressive Foundry to reduce pressure on the moulding line and focus on growing other areas of the operation. “DISA has really been the partner we’ve needed to continue growing as a modern foundry. Their innovative ideas and what they bring to the market are second to none.” Josh concludes.
