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Installations: Innovative Casting Technologies - Dualtech Foundry

In 2008 a devastating fire destroyed Dualtech's foundry. Palmer was called to replace damaged equipment — to get them quickly up-and-running. Since that time, the Dualtech Foundry had expanded several times from a conventional loop to a carousel no-bake molding system.

In 2018, they took the bold step to become one of the first foundries in the country to install thePalmer flip molder – the industry’s most advanced automated no-bake system.
Visit www.innovative-castings.com

 

Installation of the Palmer Flip Molding Machine

OVERVIEW
Innovative Casting Technologies (ICT) from its inception has always been a high-end prototype facility for some of our nation’s largest truck and heavy equipment manufacturers. Over the past fifteen years to meet production increases, this foundry expanded from a conveyor-loop based molding system to a carousel rollover-based molding system. Due to ICT’s continued expansion into complex / low production runs meant that they needed a different kind of molding system that would greatly increase the number of molds per hour within their current limited floor space.

SOLUTION
Palmer Manufacturing & Supply has been ICT’s No-Bake equipment partner for more than a decade. With an eye on both the production requirements and physical constraints, they recommended their recent introduction of the Flip Molding Machine (FMM). The FMM is a multi-platen machine where the box is filled, compacted, and struck off at one station, indexed, and then inverted to extract the mold at another station with a simple lift device (instead of a rollover).

Eliminating a rollover presented ICT with many very attractive advantages. While greatly reduced capital costs for the system is typically the most obvious advantage; the productivity increases were even more remarkable due to the elimination of a rollover’s cycle time of 2 minutes. Additionally, a rollover requires quite a bit of floor space and this too was reduced with the FMM.

RESULTS of FMM (44x4418/18)

  • Mold half cycle time of 47 seconds
  • Mold production rate of 37 complete molds per hour with 30-40 pattern changes per shift
  • Smaller molds are run with depths as shallow as 4"
  • Molds are drawn with a lift device – the depth of mold half has no appreciable effect on the production rate since there is no rollover
  • Mold box movement and draw function are all 100% automatic; the only staffing requirements consist of a mixer operator and utility person to help set sleeves and assist the mixer operator in striking off
  • Coating, coring, closing – are all accomplished in the normal manner
  • Pattern mounting system is fast enough to maintain the 37 molds per hour rate on a daily basis

"The combination of reduced costs, increased productivity, reduced floor space requirements, and reduced staffing levels has made the Palmer Flip Molding Machine a very profitable addition to our foundry," said Jack Laugle, President, Innovative Casting Technologies.

 

Photo Gallery - 2008

Click on the images (below) to enlarge, and arrows to navigate.

SPACER20

Resource Center

Video Palmer FMM at ICT Dualtech
VR FMM 3D VR Model
Video Dualtech Foundry 2016 video
Article Bold Installation of No-Bake Automation
Article Dualtech Does Damage Control after a devastating fire.
Video Examples of the Dualtech installation featured in Palmer's "No-Bake Equipment Line" video.


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