The advantages of green sand reclamation: A focus on green sand to green sand

“Green sand reclamation is a key driver of cost savings and environmental sustainability in the foundry industry. The primary advantage of green sand reclamation is its ability to reuse existing green sand in the casting process, leading to significant cost savings by reducing the need for fresh sand, while also minimising waste and promoting environmental sustainability by recycling the material within the foundry itself. This allows for a closed-loop system where used green sand can be reprocessed and reintroduced into the moulding process, maintaining consistent quality and reducing raw material consumption,” said Peter Petersen of Mondeco Solutions who are the agents for Simpson Technologies, a Norican Technology Group company.

“Most everyone realises that sand reclamation is necessary for cost reduction and environmental requirements. While the popularity of sand reclamation certainly resulted from increasing sand prices there are few processes that provide as many immediate benefits such as sand reclamation.”

The Simpson Pro-Claim minimises costs by reclaiming and reusing green sand, reducing the need for expensive new sand purchases

“A standout innovation in this space is the Simpson Pro-Claim, a system designed to reclaim and reuse sand efficiently. Mondeco Solutions have represented Simpson Technologies for a number of years now. The partnership was enhanced even more in 2022 when the Norican Group, another well-known company supplying solutions and equipment into the foundry industry, who I have represented in South Africa since 2018, acquired Simpson Technologies.”

“Here’s how the Simpson Pro-Claim is reshaping green sand processes, helping foundries cut costs and streamline operations.”

Lower operational costs
“Operational expenses can significantly impact a foundry’s profitability. The Simpson Pro-Claim minimises costs by reclaiming and reusing green sand, reducing the need for expensive new sand purchases. Its continuous operation eliminates downtime and reduces maintenance expenses. The Pro-Claim’s streamlined design features fewer moving parts, resulting in lower wear and tear, fewer replacements, and longer-lasting equipment performance.”

Energy-efficient green sand reclamation
“Energy consumption is a significant concern for foundries. Unlike traditional thermal systems that require vast amounts of electricity or natural gas, the Pro-Claim operates efficiently without any natural gas. This makes it a greener and more economical choice for green sand reclamation, reducing energy costs and minimising the foundry’s carbon footprint.”

Simplified safety and compliance
“The Simpson Pro-Claim’s design prioritises safety and regulatory compliance. Since it doesn’t involve high temperatures, thermal permits or confined space entries often required for other systems are not needed. This reduces regulatory burdens, simplifies compliance, and lowers associated costs while maintaining a safer working environment.”

Reduce disposal costs
“Disposing of used green sand can be costly. The Pro-Claim substantially decreases disposal costs by reclaiming sand for continuous use, reducing waste, and reducing landfill expenses. This results in significant financial savings while supporting sustainability goals – a selling point for customers who value eco-friendly practices.”

Enhance casting quality
“The quality of reclaimed sand is crucial for producing high-quality castings. The Simpson Pro-Claim cleans and conditions the sand, preserving its quality, achieving more consistent properties, improving surface finishes, and reducing defects. This results in reduced rework, fewer rejects, and higher customer satisfaction.”

Compact design for maximum flexibility
“Foundries often have limited space. The Pro-Claim’s compact footprint optimises floor space, allowing foundries to maximise their operational layout without significantly investing in additional infrastructure. This small footprint also means more flexibility for future expansions and equipment additions.”

Disposing of used green sand can be costly. The Pro-Claim substantially decreases disposal costs by reclaiming sand for continuous use, reducing waste, and reducing landfill expenses. This results in significant financial savings while supporting sustainability goals – a selling point for customers who value eco-friendly practices

Eliminate risks of thermal events
“Traditional thermal systems carry the risk of high-temperature accidents. The Pro-Claim, focused on green sand reclamation without the use of extreme heat, eliminates these risks, enhancing safety and reducing potential fire-related costs and insurance premiums.”

Labour savings with automated operation
“Labour is one of the highest costs in foundry operations. The Pro-Claim operates continuously without a dedicated operator, significantly reducing labour expenses while maintaining efficiency.”

Rapid Return on Investment (ROI)
“One of the key benefits of the Simpson Pro-Claim is its quick ROI. Many foundries see a return on their investment in just six months to two years, making it a financially sound choice for operations looking to enhance profitability and sustainability.”

A new era of green sand efficiency
“The Simpson Pro-Claim is transforming the way foundries approach green sand reclamation. By reducing operational costs, improving energy efficiency, lowering disposal expenses, and preserving sand quality, the Pro-Claim is a valuable asset for foundries. It’s a forward-thinking solution for foundries aiming to remain competitive while embracing sustainable and cost-effective metal casting practices.”

“Embracing the Simpson Pro-Claim secures immediate benefits and positions foundries for long-term success in a rapidly evolving industry. It’s a solid step toward more efficient and environmentally friendly green sand operations.”

For further information contact Peter Petersen of Mondeco Solutions on 079 448 1277 or email peter@mondeco.co.za or visit www.mondeco.co.za