Projects

Operational Consulting – foundry qualification and product evaluation.

Foundry Audit in Support of New Ownership

Conceptual study for a foundry expansion, engineering, provision and installation of a complete ready-to-operate Disa 2070 plant, including building for truck parts

Master Plan for No-Bake Molding

Equipment Relocation Engineering & Project Management

Master Plan for melt shop

Engineering for Disa molding line installation

Project Management for Dust Collection Audit.

Foundry Audit to determine silica source reduction opportunities

Foundry Audit to determine silica source reduction opportunities

Foundry Audit to determine silica source reduction opportunities

Master Plan for HPDC Aluminum Automotive New Metal Casting Facility

• 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

Concept & Feasibility Development for improvements to technologies to reduce labor and costs and improve lead time.

Foundry Audit to determine silica source reduction opportunities

Foundry Audit to determine silica source reduction opportunities

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.

Operational assistance in automotive/truck casting handling and finishing

Foundry Audit to determine silica source reduction opportunities

Development of Master Plan for foundry modernization and expansion

• Engineering of furnace charging system and automated alloy additions system
• Core making and assembly process upgrade

• 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

Engineering Assistance for Foundry Start-Up and Upgrade

Foundry Master Plan and Engineering review to improve operation and process flow.

Quality audit

Operational assistance for automotive foundry

Engineering of new impact molding line for the production of tubs and sinks

Finishing Department modernization and rationalization

• 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.

Master Plan to effect improvements for operational efficiency and additional capacity for plant operation.

Engineering Study for Potential Iron Foundry to produce 200,000 tons of iron components per year.

Due Diligence for acquisition of new foundry.

• Engineering study to upgrade core department.
• Foundry Audit and Automation Plan.

Engineering review for equipment relocation

Master Plan for bronze foundry focusing on increased quality, productivity, efficiency and labor reduction through process streamlining and equipment upgrades.

• Master Plan to update existing no-bake mold line.
• Detail Engineering, specifications, equipment evaluation, installation coordination, start up and training.

• Evaluating need for automated grinding needs at facility
• Specifications for quote requests
• Quotation Evaluation and equipment recommendations

Audit and Master Plan to improve wrot copper mill production facility.

Engineering for plant producing complex aerospace castings

3D design work and walk-through for greenfield foundry.

Engineering for plant modification.

• Engineering of a new, no-bake foundry
• Design Engineering & Project Management for New Bronze and Iron Glass Mold and Commercial Foundry

Relocation of foundry equipment from Muskegon to Saltillo, Mexico

Engineering, Equipment Selection, and Processes Development support for addition of automated pouring conveyors.

• Operational assistance to reduce scrap
• Tooling/pattern assistance

Engineering of complete new melting facility, including processing equipment and building

New plant design for silicon metal processing

• Foundry modernization program
• Multi scenario study & recommendations for iron melting
• Foundry sand cooling audit.

• Foundry Audit to determine silica source reduction opportunities
• Master Plan-Molding Line Relocation and Optimization
• Project Management & Engineering Foundry Melt Facility

Feasibility Study for Large Casting Facility in North America

Finishing Automation Engineering

Modernization plan for mold and core removal, shot blasting, sand handling and reclamation for this aerospace aluminum and magnesium casting plant

• 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

Engineering services relating to the post cast automation for cooling, decoring and degating of aluminum blocks

Foundry Audit to determine silica source reduction opportunities

Deisgn Engineering of a Greenfield DISA ductile iron foundry to produce ductile iron parts for automobiles

Foundry audit and concept development for new mechanized finishing department

• Engineering and master planning of foundry
• Modernization and productivity requirements for automotive and truck foundry

• Assistance in aluminum foundry acquisition
• Process improvement of large aluminum automotive foundry

Audit of melting operation

Engineering Development for Cleaning and De-Gating System

Design of new green sand foundry for the production of automotive aluminum parts

Foundry Master Plan focusing on post-shakeout processes.

• 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

Conceptual engineering for new greenfield Disa foundry

Foundry Audit to determine silica source reduction opportunities

Complete Master Plan for the modernization of a small lot jobbing no-bake and greensand foundry

Design of new no-bake foundry to produce steel castings

Foundry audit for equipment replacement.

Operational Consulting – alternative product strategy evaluation.

Foundry Master Plan with emphasis on No Bake Pouring/Cooling Line.

• Plant rationalization
• Design of complete casting facility relocation

Automatic finishing of bronze castings

Engineering of a new bronze foundry in Monterrey, Mexico

• Engineering of new impact molding system and auxiliaries.
• Engineering for foundry modernization

• Engineering of foundry modernization program
• Provision of environmental equipment

Design new plant for a complete Line for Refractory Products

5 Year Master Plan, Spun Fiber Line, Formed Fiber Line

Arc Flash Study and Uninterruptable Power Supply System

• Foundry Audit to determine silica source reduction opportunities
• New Sand System

• New Large Casting-No-Bake Foundry
• Silica Exposure Reduction Assistance

• New Match Plate System Development
• Designed and built $92 million foundry for the production of lead free water works components

Engineering of a foundry expansion/ modernization program for truck components

• 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

• Casting finishing master plan
• Mechanized Casting Finishing Phase II

• 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

Foundry Master Plan for equipment upgrades and process assistance.

Foundry Audit to determine silica source reduction opportunities

Metalcasting landscape evaluation.

Blending and packaging process improvements

Foundry Master Plan for greenfield foundry.

Foundry expansion “Master Plan” and engineering for new impact molding line

• Operational support and onsite assistance.
• Assessment for replacement of current equipment with new Inductotherm Coreless Furnace.

Engineering of sand system, Disa installation, and melting/pouring installation for aluminum automotive parts

Master Plan to improve foundry process and product flow

Foundry audit and relocation options

Expand & Combined Core Room

• 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

Conceptual engineering for a new 100,000 ton/year steel railroad parts foundry in Mexico

Operational assistance program for automotive brake parts foundry

Engineering study for automated finishing of municipal and construction castings

Fire hydrant manufacture and assembly

Engineering for hot metal handling, delivery and automatic pouring

Complete engineering, provision of equipment and installation of new 48 x 48” impact molding line, including building

Engineering study addressing the feasibility of replacing cupola with induction melt

Engineering of a complete new ductile iron, large fittings foundry

Concept study, no-bake production increase/upgrade

Complete New Lead-Free Bronze Foundry

Concept & Feasibility Development for an experimental/prototype foundry for low production investment castings.

Master Plan Feasibility for new foundry

Foundry Audit to determine silica source reduction opportunities