Foseco South Africa adds support with equipment purchase and chemical supply.
When Danie Cronje acquired Mustang Foundry in April 2023, he immediately changed the name of the company to Ferrous Castings. His plans were not just about improving the foundry’s working space, but also the equipment and general workflow of operations on the foundry floor.
“Metalcasting is a fiercely competitive industry, and maximising productivity while maintaining and safeguarding quality is a constant challenge. Achieving that balance of productivity and product quality often requires foundries to make significant investments in new machinery,” said Cronje.
“New equipment in a foundry can significantly improve various aspects of the casting process, including safety, efficiency, and the quality of the final product. Nowadays modern foundries are incorporating technologies like automated systems, advanced sand preparation and handling equipment and improved melting and pouring methods.”
“Additionally, software-driven updates also represent a blend of performance enhancements and cost-efficiency that increases moulding speeds and optimises cycle times without compromising the integrity of the moulds.”
Ferrous Castings recently installed an Endeco Omega Sinto 10-ton an hour continuous mixer supplied by Foseco South Africa
“Furthermore, suppliers and manufacturers of equipment and consumables have developed and introduced countless innovations to improve the profitability and performance of the foundry industry, which we have to take advantage of.”
“Last year we purchased a new 1 ton induction furnace. The furnaces that came with the purchase of the foundry were old and beyond repair so they ended up on the scrap heap. Thanks to the innovative addition to our melt shop the new furnace has taken us to a new level of efficiency and productivity.”
“The metalcasting industry is undergoing a significant transformation as producers integrate smart technologies. By embracing innovations like the Internet of Things (IoT), artificial intelligence (AI), and advanced automation, foundries and diecasters are enhancing their operational capabilities and redefining efficiency standards. These advanced capabilities make it possible to apply real-time data analysis and predictive maintenance, and help to streamline production processes and reduce downtime.”
“Moreover, the emphasis on process improvements is crucial to minimising waste and maximising resource utilisation, directly contributing to sustainability goals and cost savings. Adopting these advancements in a competitive global market is imperative for foundries wishing to remain relevant and profitable. By harnessing the power of technology and continually refining processes, foundries are poised to achieve greater productivity and resiliency.”
Endeco Omega Sinto 10-ton an hour continuous mixer supplied by Foseco South Africa
“We have also recently installed an Endeco Omega Sinto 10-ton an hour continuous mixer. Foseco South Africa, a division of Vesuvius South Africa, have been very supportive of the business since we acquired it in 2023. And they have continued to be so with the purchase and installation of the continuous mixer. They have many years of experience in the foundry industry and vast sources of technology experts to refer to before transferring the knowledge locally.”
“We like having access to this technology. But more importantly we like using their chemicals and the service that they provide.”
“A sand mixer is a critical piece of equipment used in foundries and metal casting operations to ensure a consistent and homogeneous mixture of sand and binders. This equipment plays a vital role in producing high-quality moulds and cores for casting processes by evenly blending the raw materials, thereby improving the strength, surface finish, and dimensional accuracy of the final castings.”
“The main purpose of a sand mixer is to prepare moulding or core sand by mixing silica sand with binders (such as clay, resin, or chemicals) and additives. The goal is to achieve a uniform mixture that ensures good mould integrity and efficient casting performance. A well-prepared sand mix reduces casting defects such as porosity, blowholes, and poor surface finishes.”
“Like the furnace the old equipment was despatched to the scrap heap.”
Ferrous Castings have also opened a new fettling shop, which is now separate from the foundry area
“Before the new equipment arrived, we could only manage to produce at best 3 tons of moulds an hour, which is very restrictive. We have now ramped this up to 10 tons an hour – that is 7 tons an hour more than we were doing previously. And we have not had to increase staff in this department.”
“The numbers vary according to what orders we have and what we are casting at the time. We can accommodate up to 1m² boxes, either in iron or steel. Currently we are casting about 30 tons a month of SG iron and cast iron and about 30 tons of steel.”
Other new equipment
“This year we have introduced a 750kg furnace and opened a new fettling shop, which is now separate from the foundry area. We also purchased a new forklift and combined our dispatching process is now a lot more efficient.”
“We also added and improved our health and safety department protocols and methods. This ensures all health and safety measures are in place and implemented in order to ensure a safe working environment for our team.”
“Going forward we want to add a 3-ton an hour mixer and an additional reclamation plant. We also looking at the upgrading of our sandblast unit and there are other developments that we will make known once they are finalised.”
“Around the world one dream unites metalcasters, regardless of their experience or specialty: greenfield capacity. It’s fine to add new melting or moulding machinery, or to update cleaning and finishing systems, but there are limits to expansion and modernisation. Cost and market opportunities are obvious constraints to many operators’ potential, but plant infrastructure, inaccessibility, and local zoning rules are often overlooked as the limiting factors to a foundry’s growth opportunities. I think South African foundry owners have more obstacles than our international counterparts but we still make it happen.”
For further information contact Ferrous Castings on TEL: 083 321 1172
