Green and foundry are not commonly interchangeable terms. However, in the case of Atlantis Foundries, these two words are about as close to that as you’ll get in this industry.

For nearly a decade, Atlantis Foundries has been a world-leader in implementing process improvements to their foundry operations, largely driven by the adoption of Industry 4.0 technologies and smart manufacturing processes.

This includes the adoption of automated moulding lines and the deployment of robots right through to artificial intelligence software to aid in the monitoring of casting defects. Over and above this, the foundry’s drive to go “green” will see it operating virtually off-grid via renewable resources very soon.

Now the foundry is about to embark on its next venture – vertical casting using the Full Core Pack method.

Atlantis Foundries have recently been in the process of commissioning and adding the final touches and testing to their new Full Core Pack (FCP) line. The new line involves vertical pouring and is well-suited to producing castings in the volumes and sizes that require complex internal cavities. The line is also modular in that Atlantis Foundries will be able to ramp up production by adding further cooling station lines to the existing automated line, for example, amongst many other modular additions and efficiency improvements

New Full Core Pack line undergoes final testing and preparations for full production
Traditionally, Atlantis Foundries uses cold box technology to facilitate the full spectrum of shapes and sizes across the engine blocks it casts for parent company Daimler Truck. Operating fully automated core dipping facilities to connect to its tunnel indexing core drying oven and using green sand moulding techniques to be able to cast the full range of automotive component grey cast iron grades for its heavy-duty engine blocks that weigh in excess of 400kg, the foundry is continuously growing its skillsets.

Now Atlantis Foundries have recently been in the process of commissioning and adding the final touches and testing to their new Full Core Pack (FCP) line. The new line involves vertical pouring and is well-suited to producing castings in the volumes and sizes that require complex internal cavities. The line is also modular in that Atlantis Foundries will be able to ramp up production by adding further cooling station lines to the existing automated line, for example, amongst many other modular additions and efficiency improvements.

Explains Cordell Rautenbach, Senior Manager Technical Engineering and Logistics at Atlantis Foundries: “We manufacture heavy-duty engine blocks and that is what we do here. Traditionally this has been done on our green sand horizontal moulding lines. As we are continuously looking at improving our efficiencies and optimising our equipment within the plant, refining our processes is something we are always looking at.”

The new FCP line has also been supplemented with a manipulator for loading and unloading of the core packs. The manipulator has six axes of movement and a lifting capacity of up to 3 600kg. It is fitted with replaceable bronze finger tips and has variable gripping force via a pressure-reducing valve, allowing the same robust unit also to handle smaller, more delicate parts. Electric force feedback in the operator’s control handle prevents damage to surrounding equipment. Features such as heavy-duty spherical roller bearings, advanced polymer shock absorbers, and high-pressure-rated cylinders and motors ensure that the manipulator is highly reliable, even in the harsh environment of the foundry

“The major difference with the FCP method as compared to our well-known horizontal method is that the entire block is now going to be cast as a complete core package. With testing on our pilot line, we have already realised significant quality efficiencies and reduced input costs. Another benefit is that the facility is scalable, and this will allow us to increase our capacity as and when we need to.”

While the FCP method is not a new method, the intellectual property lies in how to cast the full block in the core package given the constraints of having to cast such a large, heavy and complex product. While there haven’t been many major design changes to the engine blocks themselves, the new FCP process promises substantial benefits for Atlantis Foundries, over and above the anticipated cost and raw material savings.

“Firstly, what is critical in any expansion like this, and because you are driving technology, you need to realise that as a foundry, you cannot make anything without tooling. On this, we work very closely with world-renowned toolmakers to advance ourselves on that front,” continued Rautenbach.

While the FCP method is not a new method, the intellectual property lies in how to cast the full block in the core package given the constraints of having to cast such a large, heavy and complex product. While there haven’t been many major design changes to the engine blocks themselves, the new FCP process promises substantial benefits for Atlantis Foundries, over and above the anticipated cost and raw material savings

“Secondly, we collaborate closely with the original equipment manufacturers as even though there is some off-the-shelf equipment we can use for a project like this, much of it is fully customised to our needs. For the FCP line, you really need to mix and match different technologies with different suppliers to reach a solution that works for you.”

“This project has been ongoing for some time and has been through many iterations for us to reach the point where we were able to commission the pilot line. Now that we have reached the phase whereby final testing has been approved and we are happy with the process and of course, the final blocks themselves, we will be ramping up the line to full production by early 2028.”

“We have seen significant improvements in terms of the quality of the blocks themselves, as well as reduced input when it comes to finishing. Further to this the efficiencies of the process itself are also significantly better than the traditional green sand method.”

“Specifically for the new FCP line, we have invested in a new ladle pouring machine. A core feature of this pouring machine is its ability to record and analyse all process-relevant parameters, linking the pouring operation directly into the foundry’s digital Industry 4.0 data software.”

Atlantis Foundries have also invested in a new rotary sprue cleaner drum. The photo was taken during the installation period

“It uses a model-based predictive control system together with iterative optimisation software that manages material and energy use efficiently. Combined with precise casting process control, the measuring technology helps maximise the use of available melting capacity and improves overall material efficiency.”

The FCP’s vertical casting method for example, also works better for geometry complexities resulting in better material flows. It will also provide better overall stability to the core pack. Better dimensional stability leads to better optimisation stabilities.

The new FCP line has also been supplemented with a manipulator for loading and unloading of the core packs.

The manipulator has six axes of movement and a lifting capacity of up to 3 600kg. It is fitted with replaceable bronze finger tips and has variable gripping force via a pressure-reducing valve, allowing the same robust unit also to handle smaller, more delicate parts. Electric force feedback in the operator’s control handle prevents damage to surrounding equipment. Features such as heavy-duty spherical roller bearings, advanced polymer shock absorbers, and high-pressure-rated cylinders and motors ensure that the manipulator is highly reliable, even in the harsh environment of the foundry.

The machine is custom-built to Atlantis’ specifications to ensure maximum equipment efficiency and above the physical supply and commissioning of the equipment, support will be ongoing and be provided through annual inspections and upgrades to the machine’s PLC control system throughout the equipment’s lifetime.

The waste material will exit the line directly via a conveyor processing line and enter the drum where it will be rotated to remove the sand and dust and then come out clean at the end of the process when it is discharged from the drum. From here it will be transferred via another process line to a bunker before being transported via a further process line to be repoured

“We are not looking to phase out the green sand moulding line at all. In fact, the incorporation of both lines will give us greater flexibility in terms of overall production and it will also allow us to follow tighter maintenance plans going forward. Long-term, both lines will be run in the most economical manner possible,” said Rautenbach.

“We like to look at our relationships with suppliers as long-term partnerships. We don’t see these relationships as traditional ones – we really need to look at them as long-term strategies where open communication is key. Change is inevitable, what it comes down to is how you embrace that change together.”

Rotary sprue cleaner drum
Traditionally Atlantis Foundries has dealt with its waste coming off the green sand moulding line that included flashings and other waste by assigning it to a pre-prepared bunded area, after it had come off at various waste-off positions and bins along the line.

After leaving the various collection points, material would then be separated using a magnetic process and although the water that had come off the line had been segregated and treated, the reusable waste material would still end up – after separation – with sand and other impurities like dust when it was to be remelted. This would create slag and created further problems for the furnaces when it came to remelting.

Traditionally Atlantis Foundries has dealt with its waste coming off the green sand moulding line that included flashings and other waste by assigning it to a pre-prepared bunded area, after it had come off at various waste-off positions and bins along the line. After leaving the various collection points, material would then be separated using a magnetic process and although the water that had come off the line had been segregated and treated, the reusable waste material would still end up – after separation – with sand and other impurities like dust when it was to be remelted. This would create slag and created further problems for the furnaces. This process has now been replaced by a new rotary sprue cleaner drum, which was in the process of being installed

During the procurement process, Atlantis Foundries considered a number of manufacturers of rotary drums. A final decision was made on a flexible design, a focus on safety, and proven expertise in rotary drum technology. For Atlantis Foundries, the solution was an investment in sustainable operations and future cost reductions.

With the implementation of the new drum, the waste material will exit the line directly via a conveyor processing line and enter the drum where it will be rotated to remove the sand and dust and then come out clean at the end of the process when it is discharged from the drum.

From here it will be transferred via another process line to a bunker before being transported via a further process line to be repoured. Now, the sand waste, dust and other impurities are removed from the waste material. The new process also offers significant overall environmental benefits through the containment of the cleaning process.

Further developments
“We have constructed a new building that has been put up over a bunded area where we will be storing all of the waste and oils. This building was designed to prevent hazardous substances from escaping into the environment, protecting the soil, water as well as the employees,” explained Atlantis Foundries’ Engineering Manager Mike Hartung.

The sand waste, dust and other impurities are removed from the waste material. The new process also offers significant overall environmental benefits through the containment of the cleaning process

“Over and above this we have also constructed a specialised spray booth for cleaning our equipment such as the forklifts. Here waste materials are washed off with high pressure hoses and all of the waste such as oils can be safely confined to a specific area and recycled appropriately.”

“Currently under construction is our new gas farm. The building will safely house four large LPG gas tanks. The tanks will be covered with sand within the bricked structure and the area will similarly be bunded. Additionally, we are constructing our new diesel service station that will more efficiently supply our onsite diesel needs,” said Hartung.

Employee upliftment
A new canteen has been designed and renovated for the fettling team. The space has been completely overhauled and includes tributes from the past such as plaques from some of the old machinery that have been used at the foundry over the years.

Says Alan Fell, Improvement Specialist at Atlantis Foundries: “I have tried to make it as much as possible a fun place for the team. I was able to use some creative license with the project and above all, I wanted the new space to be a tribute to them and what they do – their space. I am a firm believer of the philosophy that environment influences behaviour.”

Looking ahead, Atlantis Foundries has a long-term goal of equipment standardisation. Naturally, this in turn will optimise spares availability and bring about further cost improvements. With these improvements, not only are plant efficiencies improved but areas for further efficiency improvements come to the fore – continuous improvement is something Pieter du Plessis, Atlantis Foundries’ Chief Executive Officer – says is at the core of Atlantis Foundries’ endeavours.

Currently Atlantis Foundries supplies 80% of Daimler Trucks’ engine block needs from its 420 000m2 production facility.

For further details visit www.daimlertruck.com