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