Projects
Serving Clients Around the World
Some of Our Projects
A.Stucki
Moon Township, PA
Operational Consulting – foundry qualification and product evaluation.
Aarrowcast
Shawano, WI
Foundry Audit in Support of New Ownership
Advanced Cast Products
Meadville, PA
Conceptual study for a foundry expansion, engineering, provision and installation of a complete ready-to-operate Disa 2070 plant, including building for truck parts
Allied Machinery
Richland, WI
Master Plan for No-Bake Molding
American Axle
Brewton, AL
Equipment Relocation Engineering & Project Management
American Cast Iron Pipe
Birmingham, AL
Master Plan for melt shop
Anvil Corp.
Columbia, PA
Engineering for Disa molding line installation
ASC Engineered Solutions
Columbia, PA
Project Management for Dust Collection Audit.
Atlas Foundry
Marion, IN
Foundry Audit to determine silica source reduction opportunities
Baker Manufacturing
Evansville, WI
Foundry Audit to determine silica source reduction opportunities
Bingham & Taylor
Culpeper, VA
Foundry Audit to determine silica source reduction opportunities
Bocar
Huntsville, AL
Master Plan for HPDC Aluminum Automotive New Metal Casting Facility
Boose Aluminum Foundry
Stevens, PA
- Study to identify best alternatives to improve operation and process flow while rebuilding after fire at foundry.
- Engineering and Coordination Assistance for the Sinto Removal and Installation of the Hunter XL2024
Boose Quality Castings
Cornwall, PA
Concept & Feasibility Development for improvements to technologies to reduce labor and costs and improve lead time.
Bradken
Atchison, KS
Foundry Audit to determine silica source reduction opportunities
Bradken
Tacoma, WA
Foundry Audit to determine silica source reduction opportunities
Brembo
Homer, Michigan
New 18,000 sq.m., $100 million greenfield facility for manufacturing iron brake discs – process and design engineering, building and utilities engineering and construction, equipment installation, and complete project management through start-up and commissioning.
Brillion Iron Works
Brillion, WI
Operational assistance in automotive/truck casting handling and finishing
Buck Iron
Quarryville, PA
Foundry Audit to determine silica source reduction opportunities
C.A. Lawton
De Pere, WI
Development of Master Plan for foundry modernization and expansion
Caterpillar
Toccoa, GA
- Engineering of furnace charging system and automated alloy additions system
- Core making and assembly process upgrade
Caterpillar
Mapleton, IL
- Engineering and project management for completely mechanized lines for finishing blocks and heads.
- Project management for the installation for new molding line for large blocks
- Engineering for sand system update and hot metal treatment
- Complete automated, robotic based system for finishing cylinder liners
- Conceptual study for a centrifugal casting foundry
- Complete engineering, equipment supply and implementation of a new core shop to produce large block castings for power generation
- Conceptual engineering for the automated molding handling pouring and sand removal cylinder heads
- Engineering for a completely mechanized line for automated finishing of small cylinder heads
- Engineering of large robotic blast system
- Detail engineering for the mechanized production of large power generation engine blocks
- Integration of manipulators for despruing cylinder heads
Caterpillar
Hodges, SC
Engineering Assistance for Foundry Start-Up and Upgrade
Century Foundry
Muskegon Heights, MI
Foundry Master Plan and Engineering review to improve operation and process flow.
Columbus Steel Castings
Columbus, OH
Quality audit
Confidential
Tiffin, OH
Operational assistance for automotive foundry
Confidential
Salem, OH
Engineering of new impact molding line for the production of tubs and sinks
Confidential
Chattanooga, TN
Finishing Department modernization and rationalization
Confidential
Michigan
- Master Plan for improvements to operational efficiency and planned additional capacity for foundry operation via equipment improvements, building expansion with new equipment purchase and complete process changes.
- Due Diligence Report for potential purchase of foundry facility.
Confidential
Massachusetts
Master Plan to effect improvements for operational efficiency and additional capacity for plant operation.
Confidential
Indiana
Engineering Study for Potential Iron Foundry to produce 200,000 tons of iron components per year.
Confidential
Illinois
Due Diligence for acquisition of new foundry.
Confidential
Minnesota
- Engineering study to upgrade core department.
- Foundry Audit and Automation Plan.
Confidential
Georgia
Engineering review for equipment relocation
Confidential
South Carolina
Master Plan for bronze foundry focusing on increased quality, productivity, efficiency and labor reduction through process streamlining and equipment upgrades.
Confidential
Illinois
- Master Plan to update existing no-bake mold line.
- Detail Engineering, specifications, equipment evaluation, installation coordination, start up and training.
Confidential
South Carolina
- Evaluating need for automated grinding needs at facility
- Specifications for quote requests
- Quotation Evaluation and equipment recommendations
Confidential
Arkansas
Audit and Master Plan to improve wrot copper mill production facility.
Confidential
Alabama
Engineering for plant producing complex aerospace castings
Consolidated Metco
Vancouver, WA
3D design work and walk-through for greenfield foundry.
Consolidated Precision Products
Minneapolis, MN
Engineering for plant modification.
Crown Castings
Greenwood, SC
- Engineering of a new, no-bake foundry
- Design Engineering & Project Management for New Bronze and Iron Glass Mold and Commercial Foundry
Dana
Muskegon, MI
Relocation of foundry equipment from Muskegon to Saltillo, Mexico
Davis Alloys
Sharpsville, PA
Engineering, Equipment Selection, and Processes Development support for addition of automated pouring conveyors.
Deeter Foundry
Lincoln, NE
- Operational assistance to reduce scrap
- Tooling/pattern assistance
Designed Alloy Products
Chattanooga, TN
Engineering of complete new melting facility, including processing equipment and building
Dow Corning
Carrollton, KY
New plant design for silicon metal processing
Ellwood Engineered Castings
Hubbard, OH
- Foundry modernization program
- Multi scenario study & recommendations for iron melting
- Foundry sand cooling audit.
Emerson Appleton
South Milwaukee, WI
- Foundry Audit to determine silica source reduction opportunities
- Master Plan-Molding Line Relocation and Optimization
- Project Management & Engineering Foundry Melt Facility
EQI International
North Shores, MI
Feasibility Study for Large Casting Facility in North America
Esco
Portland, OR
Finishing Automation Engineering
Fansteel
Creston, Iowa
Modernization plan for mold and core removal, shot blasting, sand handling and reclamation for this aerospace aluminum and magnesium casting plant
General Motors
Defiance, OH
- Conceptual engineering assistance for core making and robotic assembly
- Consulting and engineering services for the complete automatic finishing of V6 and V8 blocks
- Engineering for automated handling and finishing of malleable castings
General Motors
Saginaw, MI
Engineering services relating to the post cast automation for cooling, decoring and degating of aluminum blocks
Great Lakes Casting
Ludington, MI
Foundry Audit to determine silica source reduction opportunities
Grede
New River, VA
Deisgn Engineering of a Greenfield DISA ductile iron foundry to produce ductile iron parts for automobiles
Grede
New Castle, IN
Foundry audit and concept development for new mechanized finishing department
Gunite
Rockford, IL
- Engineering and master planning of foundry
- Modernization and productivity requirements for automotive and truck foundry
Harvey Industries
Westland, MI
- Assistance in aluminum foundry acquisition
- Process improvement of large aluminum automotive foundry
Heraeus Quartz
Buford, GA
Audit of melting operation
Intat
Rushville, IN
Engineering Development for Cleaning and De-Gating System
J. L. French
Sheboygan, WI
Design of new green sand foundry for the production of automotive aluminum parts
J.R Hoe
Middlesboro, KY
Foundry Master Plan focusing on post-shakeout processes.
John Deere
Waterloo, IA
- Engineering for large casting molding line
- Complete engineering, equipment supply and installation of a new sand reclamation system
- Master planning and engineering of a complete $100 million foundry modernization program
Jotul
Portland, ME
Conceptual engineering for new greenfield Disa foundry
Keihin
Greenfield, IN
Foundry Audit to determine silica source reduction opportunities
Kulp Foundry
E. Stroudsburg, PA
Complete Master Plan for the modernization of a small lot jobbing no-bake and greensand foundry
Loflin Fabrication
Denton, NC
Design of new no-bake foundry to produce steel castings
Loss Solutions Group
Bedford, OH
Foundry audit for equipment replacement.
Magnus Bearings
Freemont, NE
Operational Consulting – alternative product strategy evaluation.
Magotteaux
Pulaski, TN
Foundry Master Plan with emphasis on No Bake Pouring/Cooling Line.
Mahle
McConnelsville, OH
- Plant rationalization
- Design of complete casting facility relocation
Matthews International
Kingwood, WV
Automatic finishing of bronze castings
Matthews International
Pittsburgh, PA
Engineering of a new bronze foundry in Monterrey, Mexico
McConway & Torley
Pittsburgh, PA
- Engineering of new impact molding system and auxiliaries.
- Engineering for foundry modernization
McConway &Torley
Kutztown, PA
- Engineering of foundry modernization program
- Provision of environmental equipment
Morgan Thermal Ceramics
Emporia, KS
Design new plant for a complete Line for Refractory Products
Morgan Thermal Ceramics
Augusta, GA
5 Year Master Plan, Spun Fiber Line, Formed Fiber Line
Morgan Thermal Ceramics
Hudson, NH
Arc Flash Study and Uninterruptable Power Supply System
Mueller
Albertville, AL
- Foundry Audit to determine silica source reduction opportunities
- New Sand System
Mueller
Chattanooga, TN
- New Large Casting-No-Bake Foundry
- Silica Exposure Reduction Assistance
Mueller
Decatur, IL
- New Match Plate System Development
- Designed and built $92 million foundry for the production of lead free water works components
Navistar
Waukesha, WI
Engineering of a foundry expansion/ modernization program for truck components
Navistar
Indianapolis, IN
- Automated core storage engineering for robotic assembly line.
- Engineering for revamping the shakeout and casting cooling for Mold Line.
- Optimization of the core assemblies for the production storage and delivery of heads
- Material handling assistance for the production storage and delivery of heads
- Specifications for upgrade of the block shake-out system
- Engineering of core package handling and automated core setting for block production
- Computer simulation of hot metal production and delivery
Neenah
Neenah, Wisconsin
- Casting finishing master plan
- Mechanized Casting Finishing Phase II
Northrop Grumman
Newport News, VA
- New steel foundry greenfield study
- Automating cleaning room
- Engineering services relating to installation of new heat treating facilities for steel castings
- Engineering services relating to the upgrade of the arc furnace melt shop and AOD system
- Electrical and mechanical arc furnace melt shop upgrades
NOV
Tulsa, OK
Foundry Master Plan for equipment upgrades and process assistance.
Pacific Alloy
South Gate, CA
Foundry Audit to determine silica source reduction opportunities
Paragon Metals
Hillsdale, MI
Metalcasting landscape evaluation.
PolyOne
Bethlehem, PA
Blending and packaging process improvements
Precision Cast & Forge
Sandusky, OH
Foundry Master Plan for greenfield foundry.
Quality Castings
Orville, OH
Foundry expansion “Master Plan” and engineering for new impact molding line
Revere Copper
Rome, NY
- Operational support and onsite assistance.
- Assessment for replacement of current equipment with new Inductotherm Coreless Furnace.
Robinson Foundry
Alexander City, AL
Engineering of sand system, Disa installation, and melting/pouring installation for aluminum automotive parts
Rochester Metal Products
Rochester, IN
Master Plan to improve foundry process and product flow
Ross Sand Casting
Orrville, OH
Foundry audit and relocation options
St. Marys
St. Marys, Ohio
Expand & Combined Core Room
Star Pipe
South Coffeyville, OK
- Master Plan for Vertical Molding Line Foundry to produce water works fittings
- New Foundry Engineering & Project Management
- Foundry Expansion – Site Services – Commissioning and Training
- Silica Minimization Control Plan
Trinity Industries
Dallas, TX
Conceptual engineering for a new 100,000 ton/year steel railroad parts foundry in Mexico
TRW
Warrenton, GA
Operational assistance program for automotive brake parts foundry
U. S. Foundry
Medley, FL
Engineering study for automated finishing of municipal and construction castings
U. S. Pipe & Foundry
Chattanooga, TN
Fire hydrant manufacture and assembly
U.S. Foundry
Medley, FL
Engineering for hot metal handling, delivery and automatic pouring
Union Foundry
Anniston, AL
Complete engineering, provision of equipment and installation of new 48 x 48” impact molding line, including building
Urick Foundry
Erie, PA
Engineering study addressing the feasibility of replacing cupola with induction melt
Victaulic
Easton, PA
Engineering of a complete new ductile iron, large fittings foundry
Voestalpine Nortrak
Decatur, Illinois
Concept study, no-bake production increase/upgrade
Watts Water Technology
Franklin, NH
Complete New Lead-Free Bronze Foundry
Weir Minerals
St. Louis, MO
Concept & Feasibility Development for an experimental/prototype foundry for low production investment castings.
Wirco
Champaign, IL
Master Plan Feasibility for new foundry
Wisconsin Aluminum
Manitowoc, Wisconsin
Foundry Audit to determine silica source reduction opportunities
American Friction Brake Parts
Guelph Ontario, Canada
Conceptual engineering for automated casting facility for the production of brake parts
Blackhawk
Monterrey, MX
Engineering of Complete Expansion of the Ductile Iron Foundry
Camisa
Saltillo, Mexico
Operational assistance and audit of new cylinder liner foundry
Caterpillar
Saltillo, Mexico
Engineering and project management relating to 50% increase in capacity
Cifunsa
- Conceptual engineering of new automotive small parts foundry
- New head and block finishing concepts engineering
Confidential
Monterrey, MX
Engineering of Complete New Foundry Facility
Dana Camisa Corp.
Saltillo, Mexico
Relocation of melting/holding furnaces from USA to Mexico. Upgrade of spinner process
Eurac Foundry
Mexico City, Mexico
Project management & engineering for new vertical molding foundry producing automotive iron castings
Harvey Industries
Nuevo Loredo, MX
Aluminum Foundry Upgrade to Facilitate Cylinder Block Production
Hubbell
Juarez, Mexico
Master plan for new aluminum casting operation
Matthews
Monterrey, MX
Complete new greenfield no-bake foundry facility for bronze castings
MG Product
Juarez, Mexico
Foundry Master Plan for Growth
Mincer
Mexico City
Foundry upgrade
Nemak
Windsor, Ontario Canada
- Engineering and provision of new/modified sand system
- Engineering, equipment and installation for a “Turnkey” sand system for production of blocks
Nemak
Monterrey, Mexico
- Engineering for material handling system for V-8 aluminum blocks
- Computer simulation to optimize aluminum block finishing and cubing operation
NIBCO
Reynosa, Mexico
Bronze foundry modernization and expansion program
NovoCast
Monterrey, Mexico
Plant Relocation Engineering & Management
Technocast
Saltillo, Mexico
Engineering and equipment provision of a complete mechanized system for finishing industrial iron heads and blocks
Wescast
Wingham, Ontario Canada
- Computer simulation study to optimize core making, core delivery and core setting
- Setting of cope and drag exhaust manifold line
Confidential
Brazil
Management Consulting Services in Line of Foundry Acquisition
Corona
Medellin, Colombia
Modernization of bronze foundry
Dana Corporation
Caracas, Venezuela
Operational Assistance Program for automotive castings
Ross Mold International
Medellin, Colombia
Foundry Consolidation Program
Baran Engineering
Omer, Israel
Foundry & machining consultancy services
Brembo
Dabrowa Gornicza, Poland
New $75 million gray iron foundry – Total plant engineering, project management, equipment specifications, installation supervision, start-up and commissioning
Brembo
Ostrava, Czech Republic
Aluminum automotive foundry expansion technology and engineering
Brembo
Nanjing, China
Reconstruction of an existing foundry including new molding, melting and core-making facilities
Confidential
Netherlands
Designed and engineered process for automated greenfield foundry to produce up to 20,000 tons per year of ductile iron pipe connection components.
Confidential
Saudi Arabia
Designed and built greenfield foundry, production site, and ancillary buildings for the production of specialty steel valves and other castings for the oil and gas industry.
Confidential
Thailand
Design and Specification of a New Grinding Media Foundry
Confidential
China
Railroad bogie component foundry
Confidential
Wandon, Taiwan
Project Management, Detail Engineering & Site Support for foundry expansion.
CTS
Moscow, Russia
Marketing study
DISA
Herlev, Denmark
Conceptual layouts for fully automated aluminum foundry
Fagor
Ederlan, Spain
Quick study of automotive brake foundry automated casting finishing
Fagor
Eskoriatza, Spain
Quick study of automotive brake foundry automated casting finishing
Fagor
Luzuriaga, Spain
Quick study of engineering concept for iron block finishing system
ICT Group of Companies
St. Petersburg, Russia
Engineering for new steel railroad casting foundry
Indsur
Uzbekistan
Master Plan for Automotive Block and Head Foundry
Indsur
Saudi Arabia
Complete greenfield planning project for 20,000 sq.m. low pressure aluminum cast wheels, steering knuckles, and brake castings facility
INDSUR
Complete Engineering, Project Management and Specification of New Grinding Media & Liner Plate Foundry in the Middle East
INDSUR
India
- Complete New Foundry for Aluminum Pole Line Hardware
- Aluminum Pole Line Hardware Foundry Engineering & Project Management
Kova Foundry
Tashkent, Uzbekistan
Designed and built $50 million / 14,700 m2 greenfield foundry and machining plant for the production of industrial, commercial vehicle and automotive.
Magotteaux
Vaux-sous-Chevremont, Belgium
Process Development and foundry plan for new grinding media foundry
Mahle Corp.
Ayrshire, Scotland
- Plant rationalization
- Design of complete casting facility relocation
Matthews Bronze
Melbourne, Australia
Assistance in conversion of green sand foundry to no-bake process
Molycop
Salalah, Oman
Feasibility study for greenfield foundry.
Promtractor
Cheboksary, Russia
Study for steel foundry operational improvements
Scaw Metal
South Africa
- Foundry audit targeting product line mechanization and operational rationalization
- Rationalization and modernization of large castings steel foundry
- Locomotive frames increased capacity
- Design of Complete New G.E.T. Foundry
- Design of new, 2 x 20 ton arc furnace melt shop
Shyam Metalics
India
New Grinding Media & Related Casting