The Foundry
Fundamental to the Brockmoor process
Our foundry follows a linear disa automated process lending itself to annualised production volumes of approximately 50 pieces to 70,000 pieces across a range of +1000 live references.
The process is monitored and measured at every stage ensuring a quality end product. For more details please read below.
Iron Foundry Facts
- Metal is supplied by 2 x 8 Tonne 6KVA Medium Frequency Furnaces, which have close capture hoods and load cells. A predetermined weight of material is automatically charged into the furnaces.
- The metal having been released to the foundry, is discharged into a +GF+ converter (pure magnesium), prior to being moved to the treatment area.
- Having completed the treatment process, the metal is transferred to an ABB 6 Tonne presspour, with a nitrogen atmosphere.
- The pouring process is automatically controlled by a Cime optical system and Inoculant is added to the metal stream proportionally to the pouring rate.
- Moulds are produced on a high pressure, Disa horizontal, green sand moulding plant. Castings ranging from 2.00kg to 120.00kg are produced on this section.
- Pattern Equipment is kept in a vertical automated carousel storage system adjacent to the moulding machine.
- The sand is removed from the castings by a Jost shaker, prior to entering a Didion rotary drum. The returned sand then passes through a Schenk sand cooler and into a 160 tonne silo grading system. Milling of the sand takes place in an EIRICH high intensity mixer with automatic moisture control.
- The primary method of core production is by cold box, this being supplemented by shell-kroning.
- The castings, having passed through the Didion drum travel on a Magaldi belt, where the runners and risers are removed by Hydraulic wedges. Our in line deburring and shotblast ensures minimal manual intervention and expedient processing.
