Challenge Oil City Iron Works, Inc. is a Texas based foundry specializing in gray iron casting, ductile iron casting, iron machining, ni-resist casting, and heat treatment. They currently have two molding lines, utilizing a BMM  Molding Machine as well as a Hunter 20 molding line. Prior to contacting GK, Oil City was utilizing a rotary [...]

Challenge A Canadian metal casting facility had an existing rotary media drum that was due for replacement. They were looking to upgrade from their old style rotary drum to a state-of-the-art casting cleaning and de-gating technology that catered to their foundry process. What prompted them to look for a new solution was that the existing [...]

Challenge A Southern US foundry currently pours heavy cast parts for the construction equipment industry, with individual casting weights up to 1200 lbs. Their existing shakeout process included a non-GK variable-angle brute force shakeout that was costing them up to $25,000 per month in bearing replacement and maintenance costs. The unit had also started to [...]

Challenge: Eck Industries, Inc. is a privately-owned family business with over 62 years of experience in the aluminum foundry industry. As an ISO 9001 and ITAR certified company, Eck is capable of producing castings to the strictest quality requirements. As part of the Eck’s maintenance and quality program the company was looking to increase its [...]

Challenge A local machine assembly company has a critical media cleaning operation as part of their overall quality assurance program. Media must be returned to the supply bins at a specific minimum rate, and be classified properly to eliminate oversized metallic and debris to prevent clogging the media nozzles. An existing vibratory conveyor was in [...]

Challenge
Morrison Bros. Foundry in Dubuque Iowa had been receiving reliable service from an existing General Kinematics Two-Mass Vibratory Shakeout. However, the vibratory mold dump conveyor prior to the vibratory shakeout was showing clear signs of being past the point of good service. The vibratory conveyor that had been installed by another company exhibited trough damage, inconsistent conveyance rates, and sand sticking and build up on the trough. All these problems, compounded with difficulties in servicing the existing conveyor due to outdated design, lead Morrison Bros. to look for a new solution.

Challenge
A unique secondary aluminum producer, located in Kentucky, had recently purchased a more efficient rotary furnace to improve their foundry production. Optimum efficiency requires the furnace doors to be opened and closed in the shortest amount of time to maintain heating efficiency. To feed the new furnace, the current process involved multiple runs using a front end loader to weigh material and charge the furnace to capacity, leaving the doors open for an extended amount of time. The resulting loss of heat makes the process less efficient. With the loader having to travel 90 feet to the furnace, and then lifting up 48 inches to charge the furnace, the end user needed to find a better solution to charging their furnace.

Challenge
Customer needed a process in which castings could be cooled within an efficient space and time period with no transmittal of force to the environment as was being experienced from vibratory units provided from past suppliers, and without a re-design of the existing plant footprint.

Case Study: Melt Department Upgrades Dura-Bar® Furnace Charge System Challenge For over 40 years, Dura-Bar has been recognized as the industry leader in producing continuous cast iron. In order to meet their increased demand from customers, Dura-Bar embarked on upgrading their furnace / melt system with the latest technology, designed to achieve greater throughput and [...]