The decision to use binder systems in a foundry operation for moulds and cores is based on the evaluation of many factors. Some of the factors to consider are production rate, capital outlay, operating costs, required quality level, environmental impact, skill of labour force, existing equipment (pattern/core), and sand availability. Each foundry will develop a list of its own important factors when making this decision.

The underlying goal in the decision-making process is to produce quality castings at the lowest cost with the resources available.

When you’re preparing to invest in or to add an automated no-bake moulding system to your existing setup, there are a number of critical decisions to be made that require careful analysis. As with many design projects, the end of the process is often the best starting point. It’s a basic concept to design backwards, at all times keeping in mind the moulding process results you expect.

An Endeco Omega Sinto 8-station carousel moulding line with a 2-station pattern changeover. The key to the success of the carousel is not just its simplicity and compact space saving design but also its increased productivity. With one or two operators the carousel can easily produce 40 moulds per hour with cope and drag on the same pattern bolster

There are dozens of criteria that go into a well-designed system, but a few of the main considerations are: Mould rate per shift; mould size minimum and maximum; budget available; floor space available; staffing requirements/cost; complexity of coring; resin system; reclamation system requirements; engineering requirements; installation requirements and time available for installation / commissioning.

Mould handling systems include carousel moulding lines, rollover stripping stations, fast loop systems and manipulators. Usually the system is completed with a flood coating unit and a fully automatic mould closing machine, which eliminates the need for operators to close a mould and, especially where deep cores or very large moulds were concerned, it eliminates damage to the core whilst closing and any mould miss-match.

Carousel moulding line
Since Endeco Omega Sinto’s parent company Omega Sinto Foundry Equipment (then part of Baker Perkins) first designed the no-bake carousel moulding line back in the mid 1970’s they have installed more than 150 full plants worldwide.

Literally working like clockwork, the carousel will deliver, via a push cylinder, an empty pattern directly onto the compaction table for filling from the mixer, and at the same time send a cured mould into the rollover stripping machine

The key to the success of the carousel is not just its simplicity and compact space saving design but also its increased productivity. With one or two operators the carousel can easily produce 40 moulds per hour with cope and drag on the same pattern bolster.

Literally working like clockwork, the carousel will deliver, via a push cylinder, an empty pattern directly onto the compaction table for filling from the mixer, and at the same time send a cured mould into the rollover stripping machine.

Next, the filled pattern is powered back onto the carousel and the stripped pattern is ejected from the rollover onto the carousel, the unit then indexes one station and the cycle automatically repeats. Pattern changes can also be carried out during the operational cycle on the station in between the rollover and compaction table. The whole principle of the carousel is to produce moulds in high numbers with consistent quality, minimal labour and reduced impact on valuable foundry floor space.

The carousel is available in a six or eight station design configuration, as the demand for fast production times necessitates more cure stations. The indexing is by electric friction drive with air tensioning on the drive wheel to prevent slippage. The index positioning does not use unreliable proximity switches or sensors, but uses state of the art encoders to accurately determine each index position. This results in a highly reliable operation with zero maintenance.

There are four standard sizes of the carousel, ranging from a 600mm x 800mm pattern bolster up to a 1 600mm x 1 200mm bolster. The carousel is also versatile enough to be used for medium/large sized core production as well.

Rollover stripping station mould handling
As a leading supplier of complete mould handling systems, Endeco Omega Sinto has the capabilities to deliver rollover stripping stations to suit a multitude of different requirements.

“We understand the demands of the industry, offering durable solutions built to withstand even the most intense operational conditions. Our stripping stations are suitable for moulds from 500mm by 500mm up to 3 500mm by 2 500mm as standard, however, we can provide bespoke options up to 7 000mm in length,” explained Roy Dias, Managing Director of Endeco Omega Sinto.

Mould handling systems include carousel moulding lines, rollover stripping stations, fast loop systems and manipulators. Usually the system is completed with a flood coating unit and a fully automatic mould closing machine

Every Endeco Omega Sinto rollover stripping station features a vibration assist system for improved mould stripping. Also featuring an advanced hydraulic driven rotation system, the rollover stripping station can ensure smooth and precise rotation. The use of engineering-grade components in construction results in a system which requires very little maintenance, offering key performance in an industrial environment.

“Endeco Omega Sinto has integrated the latest forms of smart technology into each rollover stripping station. Each unit includes multiple proof-of-draw sensors, each with variable sensitivity. This delivers the option to detect multiple moulds in the common frame, offering unrivalled mould-stripping capabilities.”

Fast loop
“For foundries with larger mould handling requirements, Endeco Omega Sinto has developed a robust fast loop system. As well as catering for moulds up to a maximum size of 3 500mm by 2 500m x 880mm, the fast loop can also adapt to varying fill times, making the entire moulding process more efficient.”

“The modular design of the fast loop system allows easy configuration for individual customer needs while the integrated compaction table offers variable frequency and is complete with protective sand deflectors.”

“At Endeco Omega Sinto, we cater for all foundries and have the ability to manufacture bespoke systems up to 7 000mm where required. All equipment is made to order ensuring we can incorporate specialised features to help improve your foundry processes.”

Mould manipulators
“Endeco Omega Sinto can supply a range of mould manipulators, units which can be used to handle the mould, whether boxed or boxless. Our extensive product range includes both A-frame electric and hydraulic manipulators, with rotation as standard on electrical and hydraulic units, as well as beam-type hydraulic units. Endeco Omega Sinto can also provide integral crane controls, and if required mounted in a fixed beam monorail.”

For foundries with larger mould handling requirements, Endeco Omega Sinto has developed a robust fast loop system. As well as catering for moulds up to a maximum size of 3 500mm by 2 500mm x 880mm, the fast loop can also adapt to varying fill times, making the entire moulding process more efficient

“The A-frame style units have the ability to handle up to four tons while for heavier loads, the hydraulic beam style can handle weights of up to 15 ton.”

“Endeco Omega Sinto is also able to supply chain manipulators for large boxed moulds, capable of dealing with a wide range of weights and sizes up to 60 tons, delivering unrivalled performance under demanding conditions.”

Shuttle system
“No mould handling system is complete without including our shuttle system. Endeco Omega Sinto has designed a shuttle system for the semi-automatic production of large boxed moulds that require varying fill and stripping times. The shuttle includes a compaction table with variable frequency, transfer car, curing stations, pattern prep stations, mould stripping and coating.”

As a leading supplier of complete mould handling systems, Endeco Omega Sinto has the capabilities to deliver rollover stripping stations to suit a multitude of different requirements

“The modular design also allows individual foundries to further personalise their system with additional transfer cars for greater moulding capabilities. The shuttle includes a stripping station which locks the mould into place while enabling vertical stripping and an alcohol or water-based coating station to ensure the efficient completion of the process using quality Endeco Omega Sinto foundry equipment.”

“The system is available in eight different sizes with the ability to support moulds ranging from 880mm by 790mm through to 3 000mm by 3 000mm. Our expertise lies in our ability to configure products to suit the exact needs of our clients and therefore we can cater for a vast number of foundry designs.”

In 2015 engineering company Endeco was acquired by Omega Foundry Machinery and the company name changed to Endeco Omega Foundry Machinery. In 2018 Sintokogio Corporation of Nagoya, Japan, acquired a majority interest in Omega Foundry Machinery and the South African company name changed to Endeco Omega Sinto.

For further information contact Roy Dias of Endeco Omega Sinto on TEL: 011 907 1785 or email roy@endeco-omega.co.za or visit www.endeco-omega.co.za