From ancient times to the present day, the foundry has remained an indispensable cornerstone of industry, actively shaping the world around us with its diverse range of products. In our foundry, we therefore use advanced and highly efficient metallurgical production processes. This allows us to reliably ensure the consistent production of first-class castings with high precision.
The basic melting process takes place mainly in a pair of modern electric medium-frequency induction furnaces EGES with a capacity of 2×6 tonnes. These furnaces are also equipped with a reliable particulate emission capture system from BMD GARANT, as we place great emphasis on the environmental safety of the entire operation. Medium-frequency induction furnaces INDUCTOTHERM ELPHIAC with a capacity of 2×5 tonnes serve as backup melting equipment, allowing us to maintain uninterrupted melting processes in production at all times.
Specifically, we have long specialized in the production of gray cast iron castings in grades from ČSN 42 2415 to ČSN 42 2425, which corresponds to EN-GJL-150 / GG 15 to EN-GJL-250 / GG 25.
In addition, we also produce high-toughness ductile iron in grade ČSN 42 23 05, equivalent to EN-GJS-500-7 / GGG 50.
In the molding process, we excel particularly in casting a wide range of weights from 2 kg to 100 kg into carefully prepared molds made of synthetic bentonite-bonded sand. Our two modern automatic molding lines are equipped with machines from the renowned manufacturer Heinrich Wagner Sinto. These lines work on the proven principle of filling the sand into the flask with the pattern, followed by compressed-air impulse compaction and final squeeze pressing. Both lines also offer high flexibility for setting cores into the molds during the cycle, which optimizes all molding processes even when producing geometrically very complex castings.
One of our newest technologies is the automatic HSP 3D-2 line, which has been in full operation since January 2023. This advanced line features a segmented squeeze plate and delivers a high output of 60 complete molds per hour with flask dimensions of 850 × 850 × 200/200 mm. This enables us to fulfill even very demanding orders with maximum dimensional accuracy.
By contrast, we have been operating the proven first-generation HSP 3D-1 molding line since 2002. Its flask size is likewise 850 × 850 × 200/200 mm, but with the practical option of increasing the mold half height by up to 50 mm according to the individual requirements of the casting. With a capacity of 50 complete molds per hour, it reliably complements our overall production capabilities.
The preparation of the molding mixture is a fully automated section of our foundry. The heart of this operation is a modern mixing station equipped with a powerful MTI 2500 turbine mixer from TECHNICAL. For precise water dosing, we use the automated MICHENFELDER control system, which ensures stable moisture content and optimal properties of the sand mixtures. The molding mixture is then effectively air-cooled and, if necessary, additionally cooled with a fine water mist. This closed cycle completely eliminates the human factor and guarantees flawless mold-making processes in the long term.
For the production of sand cores, we rely above all on the modern LAEMPE LL20 core shooting machine, which allows a shot volume of up to 30 liters followed by amine gas curing for maximum strength. In addition, we also use the proven RÖPER 40 machine with a shot volume of up to 40 liters. It likewise relies on amine curing technology (the Cold-Box process), enabling us to reliably achieve high dimensional stability of the cores.
The primary transfer of hot castings from the molding lines directly to the fettling shop is handled by a reliable Magaldi apron conveyor, followed seamlessly by an efficient vibrating chute. For the safe handling of heavy parts and the removal of gating systems, our workers also have a CLANSMAN DYNAMICS hydraulic manipulator at their disposal, which significantly simplifies the entire production workflow.
The castings then undergo controlled cooling in our cooling hall, where they remain for up to 24 hours. Once fully cooled, they proceed to the KONRAD RUMP shot blasting machine with a high abrasive flow rate of 300 kg/min, which reliably removes all residues of the molding mixture and ensures a clean casting surface. The entire workstation is also fitted with a modern filtration unit, allowing us to effectively protect the surrounding environment.
In line with the individual requirements of our customers, we carry out various finishing treatments that complete all our production processes. As standard, we offer synthetic coatings in red-brown or black shades, and we also provide high-quality powder coating or hot-dip galvanizing. In addition to surface treatments, we offer comprehensive machining of castings, such as turning, milling or drilling. This is carried out both on conventional machines and on modern multi-axis NC and CNC centers.
