CPT International 4/2019

EDITORIAL 

Die-casting in focus! 

EUROGUSS trade fair will be taking place in Nuremberg in mid-January 

of next year. Most likely again with an international participation of 

more than 50 percent. Overall, the number of exhibitors has risen to 

more than 700 – who will show their innovations for the first time in 

four fully occupied exhibition halls. 

Robert Piterek 

e-mail: robert.piterek@bdguss.de 

Now, at the end of December, 

die casters have to consider two 

major upcoming events: the New 

Year and the EUROGUSS fair in mid- 

January. While the orders situation in 

the foundry industry for die-casters is 

still mostly satisfactory, iron foundries 

are coming under increasing pressure. 

Some companies, such as the Norican 

Group, therefore have drawn conclusions 

during recent years and purchased 

companies from the non-ferrous segment, 

such as furnace manufacturer 

Striko Westofen and die-casting machine 

constructor Italpresse. This increasingly 

shifts the material preference of the 

corporate group (based in Denmark) 

towards aluminum. In an interview with 

CP+T, DISA President Peter Holm Larsen 

discusses the strategic realignment of 

his parent company. 

This issue also offers other widerang 

ing articles on the topics of diecasting 

and light-metal casting: about 

digitalization in furnace construction, 

for example, or about strategic prospects 

such as the future of die-cast 

structural components. We also take a 

look at a user example of a very promising 

blast ing method for aluminum castings. 

The company report about the 

globally active die-casting plant constructor 

Oskar Frech, which celebrated 

its 70th jubilee this year, is particularly 

interesting. Frech is a successful example 

of a strong family-led SME – the 

backbone of German industry. A wealth 

of inventiveness and corporate courage 

enables Frech to withstand global competition 

with international groups. The 

Swabian company from near Stuttgart 

has also played its part in maintaining 

the very good reputation of ‘Made in 

Germany’ throughout the world. 

Last but not least, this issue also has 

an interesting story about the Lütgemeier 

foundry. It casts components for 

vehicle tuner Brabus using 3-D-printed 

molds. This therefore successfully combines 

the new technology of additive 

manufacturing with casting. it is regrettable 

though that the very successful 

international additive manufacturing 

trade fair Formnext in Frankfurt/Main 

at the end of November did not really 

show many examples of this successful 

collaboration between the two worlds. 

Have a good read and perhaps we’ll 

meet soon at EUROGUSS! 

CASTING PLANT & TECHNOLOGY 4/2019 3

CONTENTS 

FEATURES 

6 INTERVIEW 

“The acquisitions strengthen our 

aluminum expertise“ 

Interview with Peter Holm Larsen, COO and President 

of the Norican brand DISA. Robert Piterek 

8 MELTING SHOP 

Induction furnace control 

by virtual machines 

The iron foundry Adam Hönig AG improves 

transparency with a new data management system. 

Erwin Dötsch, Dietmar Mitschulat, Pierre Hacquin 

Melting furnace 4.0 – Thinking ahead, 

developing further, moving on 

Sensors and progressive automation at temperatures 

up to 900 °C: Future-proof melting operation 

thanks to long-term R&D projects. Sven-Olaf Sauke 

INTERVIEW 

Peter Holm Larsen: 

„Our aim is to connect 

all parts of the 

foundry and visualize 

it for the customer.” 

MELTING SHOP 

Via an app on a smart 

phone, the iron 

foundry Adam Hönig 

from Kempten saves 

energy and resources. 

18 DIGITALIZATION 

Foundry Group pioneers data-driven 

productivity project 

Partnership sees foundry business make multi-site 

monitoring a reality. Rudi Riedel 

21 PRESSURE DIE CASTING 

The future of structural components in HPDC 

Structural components offer a considerable light 

weight construction potential. 

Herman Jacob Roos, Martin Lagler, Luis Quintana 

FETTLING AND 

FINSHING 

Romain Zorzi, Project 

Manager New Processes, 

introduced a new 

rubber belt tumble 

blast machine for aluminium 

castings at 

the SEW Usocome 

plant in France. 

Cover-Photo: 

Fotolia 

4

CONTENTS 

LOGISTICS 

Fondium‘s iron 

foundry in Singen has 

a new forklift fleet. 

26 PRESSURE DIE CASTING 

Castings for light-weight engineering 

Cast iron and aluminium alloys as alternatives for 

thin-section steel castings. 

Wolfgang Knothe 

30 RECYCLING 

Recycling – certainly safely! 

The GreCon spark extinguishing system sees to a 

safe production at Siegfried Jacob Metal Works. 

Denis Sauerwald 

32 FETTLING AND FINISHING 

Automated blasting of aluminium castings 

A joint project in the area of surface technology 

led to an automated blasting cell for mass-produced 

castings. Ulf Kapitza 

36 LOGISTICS 

Forklift fleet keeps the castings moving 

The industrial trucks at Fondium’s production 

works in Singen have been brought up-to-date by 

forklift expert Still. Gerd Knehr 

40 COMPANY 

70 years is not enough 

The family-rund Oskar Frech group turned 70 this 

year. Its secret of success: Inventiveness and entrepreneurial 

courage. Robert Piterek 

46 3-D PRINTING 

COMPANY 

To compete successfully 

on the market 

inventiveness is 

essential for the 

Oskar Frech group. 

3-D-PRINTING 

Lütgemeier GmbH 

casts metal parts for 

car tuner Brabus 

using 3-D printed 

molds. 

With the turbo from the 3-D printer 

to 900 hp 

Vehicle technology manufacturer Lütgemeier in creases 

flexibility and productivity using Voxeljet‘s 

VX1000 3-D-printing system to supply high-performance 

car tuner Brabus. Frederik von Saldern 

COLUMNS 

3 EDITORIAL 

50 EUROGUSS NEWS 

52 NEWS IN BRIEF 

57 NEW: SUPPLIERS GUIDE 

76 FAIRS AND KONGRESSES/AD INDEX 

78 PREVIEW/IMPRINT 


INTERVIEW 

6

“Today you have to be very agile and close 

to the action, because the world is turning 

faster and faster.“ 

Peter Holm Larsen has been working for the Norican 

Group since 2007 and is currently COO and President of 

the molding machine manufacturer DISA, who is part 

of the group 

„The acquisitions strengthen our 

aluminum expertise“ 

At GIFA in June the Danish Norican Group presented itself for the first time with its four 

brands DISA, Wheelabrator, StrikoWestofen and Italpresse-Gauss. News at the stand was 

the networked foundry and zero-defect-management. In an interview with CP+T, Peter 

Holm Larsen, COO and President of the Norican brand DISA, talks about the enlarged 

group, the digitization and the outlook for the coming years. 

Photos: Martin Vogt/BDG 

Why did you buy so many companies? 

What is the big plan behind it? 

Until two years ago only DISA and 

Wheelabrator belonged to the Norican 

group. We have completely focused on 

iron casting. Although Wheelabrator 

also had other business units, it was 

mainly focused on cast iron. And DISA 

has been supplying plants to iron 

foundries for some 60 years. At the 

same time, DISA has always worked 

closely with the automotive industry 

and is increasingly moving towards aluminum. 

This trend – we all agree on 

that – will continue. Our group is part 

of a private equity fund, but regardless 

of that, our companies need to grow in 

their market. To strengthen Norican 

Group‘s aluminum capabilities, we 

acquired StrikoWestofen and Italpresse 

Gauss two years ago. Although we are 

now operating in two different material 

areas, if you look at the business 

dynamics of these industries you will 

see that there are many similarities. 

There are also some similarities in the 

technologies. And of course it is our 

intention to invest all our power in the 

company in the development of our 

brands. 

How will production become more 

efficient through the digital foundry 

you have developed? 

The conversation 

with Peter Holm 

Larsen took place 

at Norican’s GIFA 

stand. 

Our aim is to connect all parts of the 

foundry and then to visualize it for the 

customer via our cockpit. By having 

insight into all processes, they can be 

optimized. One can see where the processes 

fail and is able to fix the mistakes. 

Take the refill monitor, where a 

worker on the forklift with the ladle 

can see the level of the various furnaces 

to fill them up in time. So the furnaces 

cannot idle. This improves the 

availability of the customer with a very 

simple solution. You can reduce the 

downtime of the production line and 

the reject rate and use the data stored 

in the cloud for process optimization. 

Where will the Norican Group stand in 

10 years? 

We used to make strategic ten-year 

plans. But those times are over. Today 

you have to be very agile and close to 

the action, because the world is turning 

faster and faster. At the end of 

the day, it‘s all about understanding 

how to improve the customer‘s performance 

with technical solutions. Will we 

buy other companies in the next few 

years? Yes, I think so, because there are 

still many technologies that fit our 

business. But we will not go far from 

our core business in the foundry industry. 


MELTING SHOP 

Photos and graphics: Kemptener Eisengiesserei and ABP Induction 

engineering industry. 

Induction furnace 

control by virtual machines 

As an important step towards Industry 4.0, the iron foundry Adam Hönig AG, based in 

Kempten, Germany, has introduced a data management system which makes the foundry’s 

wide and varied production processes more transparent – by means of an App on a 

smart phone. Through the consistent acquisition and evaluation of the process data, the 

foundry saves significantly on energy and material use. 

Introducing the data management system 

placed extremely exacting 

demands on the control system of the 

two induction furnace tandems operated 

by the foundry. Here the melting 

processor Prodapt Enterprise supplied 

by the German induction furnace manufacturer 

ABP and operating in combination 

with virtual systems and an inhouse 

server left nothing to be desired. 

Erwin Dötsch, Dietmar Mitschulat, ABP Dortmund, and Pierre Hacquin, Adam Hönig AG, Kempten 

Kemptener Iron Foundry 

A family-managed company for more 

than 60 years, Kemptener Eisengießerei 

Adam Hönig AG (KE) (Figure 1), produces 

iron castings and provides advice 

in casting design mainly for mechanical 

engineering companies. Adam Hönig is 

a contract foundry with its own mouldmaking 

lines. Grey and ductile iron castings 

with item weights ranging from 

Treatment of a melt at the iron foundry Adam Hönig. 

A contract foundry with pattern making facilities and 

provider of casting design consultation, Adam Hönig 

manufactures iron castings mainly for the mechanical 

just a few kilograms up to and including 

8.5 t are produced as single pieces 

or in small and medium series in a 

hand-moulding shop or in automatic 

moulding lines (Figure 2). The sheer 

number of 6,000 to 7,000 different patterns 

gives an idea of the great variety 

of products. Figure 3 shows two impressive 

examples of medium-weight castings. 

At the foundry, 170 employees 

8

Figure 1: Adam 

Hönig Iron Foundry 

is based in Kempten, 

in the south of Germany. 

Figure 2: Casting of 

a machine bed 

weighing 8.5 t. 

Figure 3: Structural parts made of 

EN-GJS-400-15, each weighing 484 kg. 

produce about 1,000 t of good castings 

per month. Adam Hönig is certified 

according to DIN EN ISO 9001: 2019 and 

commits to high quality and environmental 

standards. 

The great number of different grades 

and casting weights calls for highly 

flexible meltshop equipment, such as 

the two induction furnace tandems 

from ABP, which both fully meet this 

requirement. Tandem 1 consists of two 

3-t crucible furnaces, type ITMK 6000, 

and a 1,800 kW/250 Hz converter for 

the power supply. The second tandem 

consists of two 6-t crucible furnaces, 

type FS 60 (Figure 4), and a 3,500 

kW/250 Hz converter. Both tandems are 

equipped with the TwinPower system 

which enables the power to be distributed 

– by electronic means - in any desired 

ratio between the two furnaces of a 

tandem [1]. 

The meltshop is a one-shift operation. 

At the end of a shift, when the last 

heat has been tapped, the hot crucible 

is charged for the first heat of the next 

production shift, and left to cool down 

to near room temperature. The next 

morning at six o’clock, the melting operation 

is resumed. For this purpose, starting 

at 3 o’clock in the morning, the 

cold 6-t furnaces are automatically switched 

on to be heated up in the cold 

start-up mode, which raises the furnace 

temperature linearly to 1,000 °C. For 

the 3-t furnaces the heating program 

starts at 4 o’clock. In this way, by 6 

o’clock, all furnaces are ready for 

full-power operation with the charge 

having reached a temperature of 

1,000 °C. 

Developments at Adam Hönig 

towards Industry 4.0 

With the support of the Kempten University 

of Applied Sciences and funding 

by the German Federal Environmental 

Foundation, Adam Hönig has 

developed a data management system 

designed to make the production process 

more transparent and optimize the 

processes in order to reduce energy and 

material use [2]. This entails the acquisition 

and evaluation of process data 

from the charge make-up and mould 

making down to the shake-out. The 

digital monitoring process is performed 

via a smart phone app. Bar code labels 

attached to the ladles and flasks, for 

example, are scanned by the staff and 

the information is sent to a database 

(Figure 5). In this way, it is possible to 

track what mould was filled at what 

time with what alloy. This information 

can be used to speed up, for example, 

the production of castings of high priority 

without having to increase the production 

capacity. Additionally, it can be 

used to further enhance the energy and 

resource efficiency because by optimizing 

the sand-metal ratio it can be assured 

that only exactly the quantity of 


MELTING SHOP 

Figure 4: The 6 t/3500 

kW induction furnace 

tandem of type ABP FS 

60. 

Figure 5: Scanning a 

bar code on a flask. 

Process data 

acquisition 

Terminal Terminal Terminal 

Charge 

make-up 

3-t tandem 

6-t tandem 

Virtual system 

Charge make-up 

Virtual system Control 

of melting furnace 

Virtual system Control 

of melting furnace 

Virtual system 

Process data 

Thermal 

analysis 

Scale 

for ladle 

treatment 

Scale for 

alloying 

elements 

Spectrometer 

Figure 6: 

Hardware concept of 

the meltshop control 

system. 

metal needed for the respective casting 

will be used, not more. 

The specific energy consumption of 

the melting furnaces of 611 kWh per t 

of molten metal is another positive 

result of the data management system. 

This value has to be considered in relation 

to the fact that the meltshop is run 

as a one-shift operation and that the 

production range is extremely diversified. 

The fact that the furnaces have to 

be heated up every day from room 

temperature means that also the heat 

stored in the refractory material has to 

be input every day anew. A second 

aspect to be considered is that whenever 

the quantities of molten metal needed 

for a production order are greater 

than the furnace capacity, long holding 

times are unavoidable. Against this 

backdrop, an energy rate of slightly 

above 600 kWh/t is a good value, achieved 

thanks to the enhanced transparency 

of the production process and of 

the associated logistics. 

In this context, the control of the 

melting furnaces plays a key role. Here 

the installation of the ABP control system 

Prodapt Enterprise in connection 

with an inhouse, virtual-system-based 

server has made the meltshop ready 

and fit to cope with the exacting requirements 

placed on it by the new data 

management system. 

Control by means of 

virtual systems 

Foundries often use PC systems that 

have larger capacities than actually needed. 

This means resources remain unused. 

In other words, the operating costs 

are higher than necessary. A way out of 

this unsatisfactory situation is the use of 

virtual systems as implemented at Adam 

Hönig. Here use has been made of a 

dedicated software that simulates hardware 

functions and generates virtual 

computers, thus enabling several computers 

with different operating systems 

to be run on one server. This leads to 

more efficient server utilization and to 

a higher availability of the applications 

because the risk of hardware failure 

decreases. Figure 6 shows the hardware 

concept for the meltshop operations at 

Adam Hönig. 

Virtual machines and the respective 

control systems for the various meltshop 

functions are installed on a central 

server. Data exchange between the 

applications on the virtual machines 

and the field components is via TCP/ 

IP-based protocols. Should any of the 

field components not be networkable, 

they will be expanded by a device that 

allows them to be connected with and 

integrated into the data exchange system 

via a connector software. 

Thus it is possible to capture basically 

all process-relevant data of the 

various meltshop functions, store it in a 

database where the data is available for 

cross-functional analyses that make the 

production process of each and every 

casting traceable all the way back. 

Monitoring these production data 

enables the foundry to detect faults at 

a very early stage so that efficient countermeasures 

can be taken early on. 

Modern plants and equipment 

monitor themselves autonomously and 

send out messages to the plant operator 

as soon as the equipment leaves its 

normal operating range. For this rea- 

10

Figure 7: Monitor-based control of the meltshop operations. 

son, the data monitoring was expanded 

to include the furnace and converter 

cooling circuits as well as the 

cooling station. The acquired data can 

be exchanged between the plant operator 

and the plant manufacturer, constituting 

another important step in the 

implementation of rule-based plant 

monitoring. 

The melting process is controlled by 

the Prodapt Enterprise melting processor, 

which will be described below in 

further detail. The charge calculator 

determines the composition of the 

charge based on the formulated recipe 

and transmits the data to the automatic 

charge make-up crane. The crane fills 

the calculated quantities of ferrous 

charge material into the charging car. 

The charge is then filled into the crucible 

in the specified quantities and 

melted. At the same time, the additives 

are manually charged from the furnace 

platform into the crucible in the quantities 

determined also by the charge calculator. 

At the end of the melting process 

a sample is taken and analyzed by a 

spectrometer. The result is compared 

with the target analysis in the charge 

calculator. From this comparison the 

additives needed for the correction of 

the charge are calculated and brought 

to the furnace platform. This process 

also takes into account the calculations 

of the additives to be added during 

ladle tapping, which are kept on the 

casting floor. 

In addition to the spectrometer analysis, 

random thermal analyses are performed 

to verify the quality of the melt. 

This is done by measuring the C and Si 

contents, and the K factor as a measure 

of the nucleation status of the melt. 

Prodapt Enterprise melting 

processor 

The Prodapt Enterprise processor from 

ABP is a solution that enables all meltshop 

operations to be controlled with 

one consistent system. It supports the 

furnace operator during the furnace 

modes sintering, melting and cold 

start-up. The process diagrams on the 

monitor inform the operator immediately 

and in great detail about the status 

of the melting process, imminent incidents 

and the current measured values 

(Figure 7). This achieves highly efficient 

furnace operation, and increases the 

availability and operating security of 

the meltshop. 

The process visualization allows the 

user – while viewing the current data 

- to also access the chronology of the 

measured values by a simple mouse 

click. Additionally, instructions for 

action in graphical or text form can be 

assigned to the individual messages 

from the fault alarm system. 

Figure 8 shows, as an example, the 

screen view of the 6-t tandem with furnaces 

3 and 4. This view appears on the 

monitor at the operating pulpit when 

the melting process is running smoothly. 

The operator receives – in a clearly 

structured view - all necessary information 

about the current process status of 

the two furnaces. The large numbers 

indicate – from the top to the bottom: 

furnace weight in kg, melt temperature 

in °C, power input in kW. The horizontal 

bar (under the illustration of the furnace) 

indicates the crucible wear, an 

aspect that will be covered below sepa- 


MELTING SHOP 

Figure 8: General view of the furnaces of the 6-t tandem. 

rately. The boxes under the green bar 

contain the charge number, the material 

number and an ID number for the 

operator. The vertical, orange bar is an 

indicator of the current power. 

By unmistakably relating the charge 

and the corresponding melt via the 

charge make-up number and the melt 

number, Prodapt Enterprise complies 

with the requirement of making the 

melting process traceable. Additionally, 

all treatment activities performed on the 

furnace are logged. The log protocol stores 

the general data of the melt and all 

treatment-related activities minute-wise. 

The treatment-related activities include 

the heating process and activities such as 

the taring of the scale, temperature 

measurement and the tappings. For each 

activity, related data such as time, duration, 

furnace content and melt temperature, 

are stored. The parameters of the 

selected steel grade and the measured 

analysis values are archived in the process 

database. 

In addition to the process data, Prodapt 

Enterprise visualizes the current status 

of the cooling, hydraulics and energy 

supply systems. In case any limits are 

exceeded or abnormal incidents occur, 

this is indicated by changing the colour 

of the respective value boxes or the corresponding 

icons. Let’s describe the furnace 

cooling system as an example of 

these detailed process views (Figure 9). 

The acquired data is displayed in a 

schematic illustration of the plant. The 

measured value boxes indicate not only 

the current value but also any exceeding 

of limits by a color change. By clicking 

on a box, the evolution of the 

value over the past eight hours can be 

viewed. The icons are animated, i.e. different 

colours indicate different statuses. 

Additionally, the system captures 

the water temperatures and quantities 

for each individual cooling circuit. Any 

deviations from trends generate warnings 

that are automatically transmitted 

to the maintenance staff. 

Swift and targeted reaction to incidents 

is essential for a high availability 

level of the meltshop. Any incident is 

firstly indicated in clear text in the head 

line of the process diagrams. The messages 

are displayed in different colours 

depending on how they are classified. 

This information is complemented by 

the “switch off” sub-view, which lists all 

incidents that may lead to the switchoff 

of the plant or the respective furnace. 

The explicit notes in the sub-view 

make it easy for the operator to assess 

the severity of an incident. Additionally, 

the responsible operator will be notified 

about the incident by text message. 

This has proved very useful especially 

during the times outside the shifts, e.g. 

during the nights, when the cold furnaces 

are being restarted automatically. 

Monitoring of the crucible wear 

In order for the meltshop to operate 

smoothly, monitoring of the crucible is 

of paramount importance. After tapping, 

when the wall surface is still dark 

red, the crucible is visually inspected. In 

addition to the visual inspection, 

> the resistance between a contact 

established to the moltenmetal and 

a coil is checked (earth-fault indicator), 

> the active power and frequency are 

measured and the results evaluated 

by means of Prodapt Enterprise. 

While the method based on earth-fault 

indication is extensively described in the 

literature [3], we here describe in greater 

detail the second method, which is 

based on the use of Prodapt data. Information 

about the crucible wear is derived 

from the change in coil inductance 

as a result of a change in the distance 

from the molten metal. Both the active 

power and the frequency increase when 

the wall thickness decreases. During 

every melting of a charge, the frequency 

is measured. The measurements 

take place under uniform conditions, 

i.e. with the furnace completely filled 

and at a defined temperature. Based on 

the result of the measurement, a wear 

index is calculated from the given 

power in each individual case and from 

the ratio between the actual voltage 

and the nominal voltage. 

The measured frequency values and 

the wear index are plotted as curves 

over time for the duration of a lining 

life. Figure 10 shows, as an example, the 

12

Figure 9. Detail view of the furnace cooling circuit. 

measurement curves for several crucible 

campaigns. At the end of the crucible 

campaign, the recorded curves are compared 

with the actual wear condition of 

the crucible and correlated. In this way, 

it is possible to derive - from the characteristics 

of these curves - the expected 

duration of a crucible campaign and the 

time at which a reline will become 

necessary. 

The advancing wear is clearly visualized 

in the process screen views, as 

shown in Figure 8. The measured frequency 

and the wear index are represented 

by the length of the green horizontal 

bar. When the crucible has been 

freshly relined, the green bar is completely 

filled. The length of the bar decreases 

as the crucible wall becomes thinner. 

The green bar disappears completely 

when the minimum wall thickness has 

been reached. 

The information derived from this 

signal has always an “integral” meaning. 

For physical reasons, the described 

method of determining the wall thickness 

based on characteristic measured 

values always refers to the complete 

crucible in the area of the active coil. 

Any localized lining wear, such as an 

“elephant’s foot” or annular erosions, 

are detected during the regular visual 

inspections of the empty, red-hot crucible. 

In combination with these visual 

checks, the “integral” system assures a 

reliable and straightforward assessment 

of the crucible wear. 

Figure 10: Detail picture of a crucible wear diagram (red: course of the frequency, 

blue: course of the wear number). 

Outlook 

While we have already achieved many 

important benefits from the consistent 

data management so far, there is more 

potential available. To tap this potential, 

we, the plant operator, work closely 

with the plant manufacturer. It 

may become possible, for example, to 

use the results from the thermal analysis 

more efficiently for an enhancement 

of the melt quality. It is also conceivable 

to develop algorithms from 

the available data, which facilitate and 

help to further enhance the coordination 

between the meltshop and the 

mouldmaking staff, making processes 

even more efficient. Another conceivable 

function would be to determine 

where in the process chain specific 

quality features are influenced and – 

vice versa - to correlate these features 

with specific instances of the process 

chain. Based on the acquired process 

data and the evaluation of tolerances, 

deviations in the production process 

may be used to identify weaknesses, 

for example, by means of automatically 

generated algorithms specifically 

designed for the requirements of 

foundry processes. 

www.abpinduction.com 

www.ke-ag.de 

References: 

www.cpt-international.com 


MELTING SHOP 

14

Demonstrator for a measuring technique for the sensor 

detection of the furnace chamber. 

Melting furnace 4.0 - Thinking 

ahead, developing further, 

moving on 

Sensors and progressive automation at temperatures up to 900 °C: Future-proof 

melting operation thanks to long-term R&D projects 

Sven-Olaf Sauke, head of R & D at ZPF GmbH, Siegelsbach 

Photos: zpf 

The future is moving inexorably 

towards smart factories, but many 

smelting plants are still stuck with 

their assembly line production in industry 

2.0 without IT support. Central elements 

of a modern factory of the 21st 

century, such as the interface to a central 

database server or an intelligent, yet 

heat-resistant automation including 

sensor technology enabling all facilities 

to communicate with each other, are 

frequently not available. Although 

there are numerous protocols for this 

purpose, the possibility of retrofitting 

these protocols standards does not exist 

in many older facilities. A lack of expenditure 

resources and the absence of visions 

for the future have often led to 

missed opportunities. Therefore, research 

strategies that build on each other 

are always recommended in order to 

keep up with the times. Only in this way 

can a smelting plant face the numerous 

challenges of the future in the long 

term. ZPF GmbH has been investing for 

years in close cooperation with various 

universities, supported by the German 

Federal Ministry for Economic Affairs 

and Energy (BMWi) and other research 

sponsors, in order to meet the current 

requirements of the industry and create 

a basis for innovative products. 

A major challenge in industry 4.0 is 

currently the automation of so-called 

predictive maintenance. In this process, 

the machine park is monitored on an 

ongoing basis and throughout the 

entire process (continuous system monitoring) 

to perform condition-based 

maintenance work. In a Smart Factory 

Moveable burner system that can be continuously aligned to the melting charge via the recorded 

measurement data and thus increases the efficiency of the overall system. 

with a melting furnace, for example, 

cleaning could be carried out by a robot 

that knows all the parameters of a furnace 

and can take action in good time 

already before a critical degree of contamination 

is reached. Consequently, the 

robot automatically prevents a later 

complete breakdown of the system and 

a standstill of the entire machine park 

in just a few minutes. 

However, as long as there is no suitable 

and at the same time safe sensor 

technology that can withstand the extremely 

high temperatures, these essential 

parameters cannot be recorded, 

even though they are the basis for 

industry 4.0. In order to master these 

complex automation tasks, the entire 

factory needs extensive knowledge of 

all important plant data - from the filling 

level of the furnace to the degree 

of contamination in the bath area. For 

this reason, ZPF, for example, has 

already laid the foundations for solutions 

for intelligently networked melting 

furnaces through various research 

projects in the past. 

Enoptal – from refractory materials 

to burner technology 

At this point, the ZPF project „Enoptal“ 

serves as an example for the beginning 


MELTING SHOP 

of such a research chain. As a result of 

the climate policy surrounding Directive 

2009/29/EC, aluminium producers and 

processors with a total rated thermal 

input of 20 MW had to limit their CO 2 

emissions from 2013 and purchase new 

certificates if necessary. This put pressure 

on companies in the aluminium 

industry to find timely solutions for 

lower CO 2 

emissions. Following this, 

more investment was made in the 

development of efficient burner technology 

to reduce energy costs and 

reduce the impact of greenhouse gases 

on the environment. The charging 

methods and cleaning intervals of the 

furnaces as well as the melting losses 

were examined and the influence these 

parameters have on the critical emission 

values. 

The research project „Enoptal“ was 

funded by the German Federal Ministry 

for Economic Affairs and Energy, supervized 

by the Project Administrator 

Jülich, conducted together with the 

Technical University Bergakademie Freiberg 

and successfully completed in 

2011. With the help of various field 

tests, the essential parameters of a melting 

and holding furnace with a melting 

capacity of 300 kg/h and a holding 

capacity of 700 kg were determined 

and optimization potential was identified 

for the refractory material and the 

burner arrangement resulting in energy 

savings of up to 10 percent. These fundamental 

results formed the basis for 

the next major research project. 

Edusal-I + II – from burner technology 

to sensor technology 

As the next step in this research chain, 

the melting plant together with other 

plant components was at the centre of 

the task in order to optimize the entire 

furnace system. The aim was to search 

for further energy saving potentials in 

melting processes with aluminium, to 

minimise melting loss, to improve process 

monitoring and to create the basis 

for a modern and efficient heat recovery 

system. 

Since the field of „measurement 

technology“ in particular has large 

gaps, the possibilities for a system for 

monitoring and control were examined 

in cooperation with the Federal Ministry 

for Economic Affairs and Energy, 

the Technical University Bergakademie 

Freiberg and the Leibniz University of 

Hanover. The focus in the projects 

„Edusal-I and II“ was mainly on the 

development of a measuring technique 

for the sensory detection of the furnace 

chamber. 

In some areas, water-cooled, optical 

systems are used for furnace interior 

monitoring – for example after the 

repair of glass troughs. Although these 

provide an insight into the condition 

of the refractory lining and other process 

parameters, for safety reasons 

they cannot be used in rough everyday 

operation or must not be used by operators 

of aluminium melting plants. If 

such a system is damaged and the 

water is unintentionally heated from 

20 °C to 900 °C, the sudden change in 

volume of the water can lead to explosions 

and thus to serious damage to 

property and persons. For the first 

time, the measurement method 

developed with the associated software 

made it possible to precisely 

determine the amount and position of 

material on the melting bridge during 

melting operation. In this context, a 

dynamic burner system was developed 

that can be regularly aligned to the 

melting charge via the recorded measurement 

data and thus increases the 

efficiency of the overall system. 

In addition, the plant was equipped 

with a heat exchanger system. With the 

help of the exhaust gas, the required 

burner air is heated in the heat exchanger 

and directed to the burners. This 

heating results in a higher temperature 

level during the combustion process and 

leads to significant gas savings. Due to 

the design of the system, a series product 

could be generated directly from 

research. The research project ended 

successfully in 2016 and enabled a 

ZPF GMBH 

The ZPF GmbH was established in 2013 from ZPF therm Maschinenbau GmbH, 

which was founded in 1993, and - like its predecessor - focuses on the 

development, design and manufacture of highly efficient aluminium melting 

furnaces. The product range also includes chip melting and holding furnaces. 

The systems are produced at the plant in Siegelsbach, Baden-Wuerttemberg, 

and where possible already pre-assembled, are delivered to metal processing 

companies worldwide. 

further increase in energy efficiency of 

up to 15 percent in the melting plant. 

On this basis, assemblies were revised 

for series use. Today there are already 

plants for trial operation, which have 

been successfully used there. The measured 

values from the research project 

are confirmed at these plants in the 

rough melting operation. 

AlSO 4.0 – from sensor 

technology to automation 

Thanks to the findings from the Edusal 

II project on sensor technology, a 

non-contact optical test method was 

developed which detects a change in 

the state of the aluminium block. 

This is a camera system with a special 

evaluation logic that is able to 

detect non-molten aluminium on the 

bridge during the melting process. This 

new sensor technology enables an 

objective evaluation of the melting 

process in the aluminium furnace and 

the user can automatically determine 

the current quantities of the material 

to be molten. In this way, characteristic 

values can be derived for objective 

evaluation of the melting performance 

guaranteeing continuous monitoring 

throughout the entire melting process. 

It also opens up further possibilities for 

automatic control processes within a 

Smart Factory. 

All results of these research projects 

serve as a basis for the current project 

called AlSO 4.0 (Aluminium melting furnace 

4.0). 

Research on control and evaluation 

options for automation, required for 

further steps in the process chain, is 

conducted in close cooperation with the 

Technical University Bergakademie Freiberg, 

the University of Bremen and the 

Leibniz University of Hanover as well as 

aluminium melting furnace operator 

and is funded by the German Federal 

Ministry for Economic Affairs and 

Energy. In this process, the areas to be 

examined are extended to the entire 

furnace system and the first prerequisites 

are created for integrating adjacent 

peripherals and achieving the desired 

increase in efficiency. The frequently 

described scarcity of resources will be 

the driver for further technical development, 

which cannot be achieved 

without research work. Long-term and 

systematic research pays off. 

www.zpf-gmbh.de 

16

MOTIVATED 

BY CHALLENGES 

Casting service 

The retrofitting of existing die-casting systems and trimming presses has been a key strength of Antrok for many 

years. As a long-term partner, we support casting plants well beyond retrofitting, providing a specialised range of 

services in all upstream and downstream performance areas that are all to do with optimising your production and 

increasing your profitability. 

– Retrofitting die-casting systems 

– Partial retrofitting 

– Retrofitting trimming presses 

– Casting cell assembly and customized constructions 

– Inspection and measurement 

– Mould and punch maintenance 

– Plant servicing 

WWW.ANTROK.DE/EN

DIGITALIZATION 

Group production site. 

Foundry Group pioneers 

data-driven productivity project 

Partnership sees foundry business make multi-site monitoring a reality. 

Work in progress in the 

melting shop of a MAT Foundry 

Rudi Riedel, President Norican Digital GmbH, Munich 

Photo: Norican 

What if retrospective analysis 

of casting production could 

be replaced by real-time 

process awareness? If reactive, afterthe-fact 

responses to sub-optimal output 

could be replaced by proactive 

foundry management? What if we 

could see at any time, not just how one 

site is performing, but how multiple 

global sites are performing in relation 

to each other? 

These are all questions MAT Foundry 

Group, Poole, United Kingdom, were 

asking. They were approached by longterm 

supplier Norican Group with a proposition 

– one solution that would answer 

all their questions, boost 

productivity and make the need to 

wonder ‘what if’, redundant. 

Unifying the equipment and extensive 

foundry solutions expertise of DISA 

and Wheelabrator, and the digital 

know-how of Norican Digital, an IIoT 

solution built around Norican’s Monitizer 

platform is now in place. This will 

allow MAT Foundry Group to collect, 

monitor and analyze complete foundry 

data – initially from two of its key 

EURAC sites, Poole (UK) and Hradec 

(Czech Republic) – to fulfil its productivity 

ambitions. 

Kick-starting a pioneering 

digital collaboration 

Comprizing 7 foundries and 8 businesses 

located across three continents, MAT 

Foundry Group is a world-renowned 

specialist in the engineering and manufacture 

of cast and machined parts for 

the automotive sector. 

Prior to the Group’s formation in 

2015, the separate companies and respective 

foundries were run as standalone 

businesses. On bringing the different 

entities together under one roof, 

the need to identify shared operating 

threads and strategic partnerships 

became clear. For Shaun Lindfield, Head 

18

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benchmark 

part now 

3D Core & Mold Printing 

“All of our foundries have one thing in common,” explained Shaun. 

“They all run Disamatic molding lines and use Wheelabrator shot 

blasting technology. Working with Norican more closely to achieve 

servicing, support and costing benefits across the Group was a clear 

priority. We wanted to create a strong alliance that would allow us 

to get the best of everything.” 

Ready for 

Production 

of Procurement for MAT Foundry Group, Norican was an 

obvious choice. 

Four years on, that alliance has proven successful and is 

helping MAT Group achieve its ambitions. “Simply put”, said 

Shaun “we know we are always getting the very latest in 

foundry solutions, services and processes. We trust Norican to 

push us forward. We want to pioneer new things and know 

Norican can help us do it. 

“One such ‘new thing’ we’d been thinking about more 

and more, was how we could do more with our data. Get 

more value from it. So when Norican approached us last year 

to see if we would like to pilot one of the industry’s first multi-site 

cloud-based solutions, we didn’t hesitate.” 

Getting to the heart of what matters with KPIs 

Norican‘s Monitizer pairs the data capture and analysis capabilities 

of the on-premise Monitizer CIM (Computer Integrated 

Manufacturing) platform with NoriGate technology. The 

solution can pull, collate, correlate and display meaningful 

data from any connected foundry machine (not just Norican 

equipment) and – thanks to the Cloud – from any geographical 

location, enabling site comparisons. Authorized users can 

simply log into their online portal and, at the click of a button, 

see a digital picture of foundry operations. But in order 

to deliver optimal results, a personal approach is needed. The 

end solution must reveal actionable information tailored to 

each customer. 

“Data for data’s sake is pointless,” said Markus Bremer, 

Norican’s Senior Vice President Sales & Service Europe – West, 

and manager of the MAT Foundry Group project. “It’s only 

meaningful when it shows what a customer needs it to show. 

So, we sat down with MAT’s senior team, site managers, production 

team and engineers from Poole and Hradec, to look 

at the KPIs that would have the biggest impact on operations”. 

With these identified, work began on designing specific 

mini systems – ‘digital cupcakes’ – that utilize Norican’s Monitizer 

capabilities to create a complete solution that’s tailored 

to MAT’s specific needs. 

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www.exone.com

DIGITALIZATION 

“If we know we’re running at 85 % in terms of tonnes per hour, we can investigate why straight 

away. It might be that we’re not producing molds quick enough. Again, we can ask why 

and perhaps discover that it’s because we need extra staff to keep up. The point is, if you 

don’t know, you can’t improve. With the solution and monitoring parameters we’ve agreed 

with Norican, we can.” 

Real time productivity – 

the real priority 

The two priorities that emerged from 

this consultation stage were tracking 

machine performance against specified 

standards and checking productivity in 

real time by monitoring metrics like poured 

tonnes per hour, molds not poured 

and bottlenecks (stop/wait times). “Ultimately, 

you can’t sell what you don’t 

make,” commented Andrew Wren, MAT 

Foundry Group’s Head of Engineering 

Projects. “That’s why these monitoring 

objectives were top of our list. 

Making what’s possible, practical 

All new Norican machinery is Industry 

4.0 ready but Norican worked with 

Shaun and Andrew to upgrade MAT 

Foundry Group’s existing equipment 

and retrofit the necessary data capture 

and IoT technology so it could be part 

of the global picture. In fact, a key 

benefit of Norican’s solution is this ability 

to upgrade legacy foundry plant so 

it can feed valuable data to the Monitizer 

system. 

The Norican solution is also designed 

to flex around a customer’s needs and 

display information in a way that is 

going to be most useful for the recipient. 

For MAT, this was a big attraction. 

“Our CEO doesn’t need to see specific 

sensor data, pressure readings or any 

such granular detail,” continued Shaun. 

“He does need to be able to log on and 

see, on one dashboard, a simple set of 

“Our production managers may need more 

detail but only for their specific site, while 

on our shop floor, our team are likely to get 

more benefit from simple green/red colourcoded 

screens linked to live data so they can 

quickly spot and fix small technical issues 

that might otherwise grow into big productivity 

problems. 

indicators from both sites which show if 

we are meeting daily targets – and if 

not, why not. 

Broader benefits: predictive 

maintenance, monitoring 

emissions 

Still linked to productivity but a step 

beyond the initial monitoring capability, 

another ‘cupcake’ is also being 

developed to support MAT’s predictive 

maintenance strategy for shot blasting 

at both sites. With the new digital solution, 

in addition to making performance 

indicators such as blasting times, 

batch count and loading/unloading 

times visible, it will now be possible to 

pull and display data relating to vibration 

levels – a key factor in blast wheel 

wear. By setting alerts against vibration 

thresholds, MAT Foundry Group will be 

able to see when servicing or replacements 

are required and avoid unnecessary, 

unplanned downtime. 

In addition to monitoring common 

KPIs across both pilot sites, the digital 

project also supports objectives specific 

to each foundry. “Basically the door has 

been opened to wider areas of business 

improvement that we hadn’t necessarily 

foreseen,” said Andrew. 

“Currently, we have to have a person 

walk the dust collectors every day 

to check differential pressure readings 

which indicate the effectiveness of our 

filters” added Shaun. “If we get a 

blockage, it’s not only a potential issue 

in terms of emissions, it’s a risk factor 

for our internal environment and staff. 

With the new Norican solution, we can 

pull data from our dust collectors into 

the mix and get a live picture of filter 

performance. We can demonstrate to 

local authorities we are constantly, and 

responsibly, on top of things.” 

Optimizing worldwide processes 

with meaningful data 

Beyond the initial two-site pilot phase of 

the project, MAT Foundry Group has big 

ambitions for where Norican’s Monitizer 

solution can take them. Andrew says: 

“We’ve actually tried to look at data 

monitoring as an operational improvement 

measure before but attempts have 

fallen flat because we just couldn’t find 

the right mechanism or get buy-in from 

the team. With this project, that’s 

changed. Our ambition, once we review 

this pilot phase, is to connect all the 

foundries in our group. That holds exciting 

potential as you can begin to benchmark 

beyond foundry walls. If seemingly 

identical lines are producing different 

results in two sites, why is that? With our 

new framework, we can find out and 

make sure best practice systems and processes 

are then shared across our global 

network. We are still in our infancy as a 

unified group. Tools such as this can help 

speed up our maturing process quickly 

and profitably. Long term success means 

grasping opportunities to boost productivity 

with both hands. With Norican, 

that’s what we are doing”, he concludes. 

www.noricangroup.com 

www.matfoundrygroup.com 

20

PRESSURE DIE CASTING 

Photo: Bühler AG 

The future of structural 

components in HPDC 

Die-cast structural components 

offer enormous potential for 

weight and cost minimization 

in the automotive industry. 

Fundamental changes in the automotive industry with a profound impact on the industry 

await foundries all over the world. Consumer demand and environmental regulations 

have changed the way how people want to use cars, as well as the requirements 

for cars. Consequently, automotive manufacturers seek the obligation to produce sustainable 

vehicles – at the lowest possible costs. One of the measures to reduce fuel 

consumption, larger battery range or less emissions is the production of lighter cars. 

Here, structural components offer an enormous technological and economical potential. 

Herman Jacob Roos and Martin Lagler, Bühler AG, and Luis Quintana, BuhlerPrince Inc. 

The continuing quest for lighter-weight 

components in the 

automotive industry has seen the 

emergence of a lucrative new market 

for die casting: structural components. 

The demand for these large, complex 

components, such as shock towers and 

longitudinal beams, was estimated to 

cover just under 6 million cars in 2018, 

many with multiple structural components. 

Current usage is predicted to 

grow to nearly 9 million cars by 2025 

[1]. But whilst these structural components 

offer a more rigid, lighter solution 

that car makers want, the cost for 

longer production runs has so far limited 

adoption to sports cars, luxury cars, 

SUVs and quality D segment saloons, 

where smaller runs make economic 

sense. But the economics of die casting 

are changing. Over the past few years, 

the costs of structural components have 

dropped by as much as 20 percent. This 

paper shows how a combination of 



High usage 

Medium usage 

Low usage 

> 6 large components 

• S sport coupés 

• F luxury cars 

4-6 large components 

• E executive cars 

• J sport utility cars 

1-3 large components 

• D large cars 

• E executive cars 

Exemplary 

components 

 

 

 

 

 

Front shock towers 

Rear shock towers 

Longitudinal beams 

Firewall 

Other 

Exemplary 

components 

 

 

 




Firewall 

Other 

Exemplary 

components 

 

 




Firewall 

Other 

Source: Roland Berger 

Graphics: Roland Berger 

Figure 1: Current usage for structural components in the automotive market. 

advanced thermal management, the 

use of new alloys and careful product 

design could drive down production 

costs even further. Hereby die-cast structural 

components get more cost-effective 

for the mass car market. With new 

car production predicted to hit the 110 

million vehicle mark in 20231, and with 

between two and six structural components 

per car, these technological 

advances could potentially transform 

the opportunity for die casters around 

the world. If the manufacturing chain 

– from die-casting machine manufacturers, 

to foundries and OEMs – work 

together, it will be possible. 

3.3 

0.6 

0.5 

2.2 

5.9 

0.7 

2.2 

3.1 

+3 m units 

8.2 

0.8 

3.3 

4.0 

8.9 

0.8 

3.8 

4.4 

High user 

(>6 parts) 

Medium user 

(4-6 parts) 

Low user 

(1-3 parts) 

Why are die-cast structural components 

so attractive to the automotive 

industry? 

Die-casting foundries around the world 

are seeing fundamental changes in the 

automotive industry that are profoundly 

affecting the industry. Consumer 

demand and environmental regulation 

is driving significant changes in the 

kind of cars people want to drive and 

how they want to use them. Electric 

mobility is developing at a fast pace, 

with global sales more than doubling, 

from around 2 million in 2017 to 5.1 

million in 2018 [2]. 

Every car manufacturer is focused on 

producing more sustainable vehicles – 

preferably at a lower cost. And a key 

element in reducing fuel consumption, 

extending battery range or reducing 

emissions, is in making cars that weigh 

less. This is the motivation that is fueling 

the growing demand for structural 

components. 

2015 

2018 

vehicle architectures in million units 

The role of die-casting technology 

in vehicle weight reduction 

Die casting large structural components 

is a proven route to reduce weight in 

vehicles. Die casting in aluminum alloys 

delivers exceptional strength and good 

formability, but with less weight than 

traditional steel structures. 

This drive for lighter weight is independent 

of powertrain selection. As 

debates over the best sustainable motoring 

solutions rage, from ICE, PHEV, 

HEV, EV even hydrogen, and consumer 

attitudes and regional and local regulation 

skew demand across markets, 

investing in the production of structural 

components is a clear strategic solution 

for many die-casting foundries. 

2021 

2025 

Figure 2: Predicted growth in current structural components, 2015 to 2025. 

Pioneered in the German luxury car 

market, die-cast structural components 

are now being used in wider categories 

of vehicle, for a range of applications. 

(Figure 1). 

An important application 

for die casting 

S sport coupés and F segment luxury 

cars currently use the widest range of 

die-cast structural components, including 

front and rear shock towers and 

longitudinal beams designed for the 

dissipation of crash energy. The Jaguar 

I-PACE actually uses 15 structural components 

on each vehicle. E segment 

executive cars and J segment sports utilities 

use die-cast components in shock 

22

Situation Today 

Today’s Market of Structural Components 

Goal for 2030 

Future Market of Structural Components 

J sport utility cars… 

S sport coupés 

F luxury cars 

E executive cars 

D large cars 

C medium cars 

B small cars 

A: mini cars 

0 10 20 30 40 

Mio Cars with structural components 

Mio Cars without Structral componets 

~ 6 m 

units 

J sport utility cars… 

S sport coupés 

F luxury cars 

E executive cars 

D large cars 

C medium cars 

B small cars 

A: mini cars 

0 10 20 30 40 

Mio Cars with structural components 

Mio Cars without Structral components 

~ 25 m 

units 

Graphics: Bühler AG 

Figure 3: Potential structural component market growth with production cost savings. 

towers and rocker rein enforcements. 

Mercedes C-class is perhaps the highest 

volume user, with around 400,000 cars 

sold each year. D-segment large cars 

use die-cast parts for front shock towers 

and tunnel reinforcement. 

This move to die casting structural 

components is gathering momentum 

around the world. Bühler analysis of 

this current available market, conducted 

by global consulting firm, Roland 

Berger (see Figure 2), shows growth in 

units is predicted to almost triple in 

the 10 years from 2015 to 2025, from 

3.3 million units to 8.9 million [3]. The 

study takes into account the currently 

known production starts of the OEMs. 

New platforms could further increase 

the demand for structural components. 

Much of this growth is predicted to 

come from the E segment and D segment 

car market, and J segment sport 

utility vehicles. 

The potential for mass market 

adoption 

The current reality is that while the 

investment costs for tools are low compared 

to other processes, the tools are 

subjected to considerably more wear 

which, in turn, increases the tool maintenance 

costs for longer production 

numbers. This currently makes overall 

unit costs too high to break into the C 

segment medium car market, or smaller 

mass market cars. 

The Bühler analysis shows that 

achieving cost savings that allow a breakthrough 

into the C segment market, 

together with greater adoption in 

existing car segments, could be a 

Cycle time [s] 

100 

90 

80 

70 

60 

50 

40 

30 

20 

10 

0 

90s 

22 

15 

18 

12 

8 

10 

10 

18 

6 

6 

12 

8 

8 

6.5 6.5 

12 9 9 

8 8.5 8.5 

2 Cavity Shock Tower 2 Cavity Shock Tower 

(4,000 ton DCM) (Carat 440 c) 

game-changer for the industry (see 

Figure 3), expanding the market from 

six million cars today, to over 25 million 

by 2030. 

So the question is, what advances 

and techniques could be deployed now, 

with current technology, which would 

enable die-casting to break the cost 

barrier to mass market adoption? 

Three technological advances within 

our grasp 

Using application knowledge gained 

across Europe, China and North America, 

Bühler has identified three areas 

where application-specific developments 

could deliver the production 

cost-savings the industry needs: 

> Thermal Management 

60s 

Potential 

(Thermal balance & 

micro-spraying) 

Figure 4: How better thermal management can reduce cycle times by up to a third. 

Spraying 

Extraction 

Opening 

Solidification 

Injection 

Dosing 

Closing 

> Alloy Selection 

> Lightweight Construction by Product 

Design 

Using an advanced 4,400 ton machine, 

and assuming an application with two 

cavities with a three-plate tool, calculations 

show that using advanced 

techniques to reduce cycle times and 

improve die lifetimes will deliver significant 

cost reductions. 

Improving productivity through thermal 

management 

Thermal management is a key element 

in cycle times, die life and part quality. 

Improving thermal management in an 

existing process can therefore deliver 

improvement in all three of these areas. 



30.00 

25.00 

20.00 

15.00 

10.00 

5.00 

0.00 

28€ 

4,000 g Shock Tower 

2-cav. & 3-plate tool 

(Baseline) 

A combination of improved thermal 

balance and the addition of targeted 

micro-spraying, together with optimum 

cell layout, can reduce cycle times for a 

typical structural shock tower by a third, 

from 90 seconds to just 60 seconds (see 

Figure 4). 

A well designed temperature concept 

allows the use of micro-spraying. This 

leads to a shorter solidification time and 

a significantly shorter cycle time. Productivity 

and quality are also improved. 

Improved thermal management also 

puts less wear on the die, extending die 

lifetime. In this example, it is calculated 

die lifetime could increase from 80,000 to 

at least 120,000 cycles, an improvement 

of 50 % or more. This is a significant 

advantage for mass market production. 

- 10% 

25€ 

faster cycle (90 s vs. 60 s) 

extented die lifetime (+50 %) 

less scrap (5 % vs. 3 %) 

Operation costs 

Metal costs 

Die & tooling costs 

Peripheral woking costs (Trimming, Deburring, HT, Straightening,…) 

Machining costs 

Figure 5: Cost reduction using improved thermal management. 

Standard 

Structural 

Alloys 

Additional 

Tooling 

costs 

+ 5% 

Source: Bühler manufacturing cost saving study 

New 

Alloy 

Systems 

High Strength 

Alloy Systems 

Alloy System AlSi10MnMg AlMg4Fe2 AlMg6Si2MnZr 

HT T7 F T5 

UTM 

Rm [MPa] 

Yield strength 

Rp0,2% [MPa] 

Elongation 

A [%] 

200-240 240-260 350-380 

120-140 120-140 230-250 

10-20 10-22 8-12 

Figure 6: Possibilities of different alloy systems for Structural components. 

And this fine-tuning of the thermal 

process avoids hot spots and reduces 

shrinkage porosity – improving 

part-quality. This could reduce scrap 

rate from 5 to 3%, once again reducing 

overall production costs. 

Cost savings for a typical shock tower 

This combination of cycle time reduction, 

extended die life and scrap reduction, 

even with the need for some additional 

tooling, has the potential to 

reduce unit production costs by 10 % – 

an important first step in achieving an 

acceptable cost for mass market adoption 

(see Figure 5). 

Using new alloys to reduce process 

steps 

Many of the structural components 

currently being produced with die casting 

play an important role in safety or 

crash damage mitigation. To meet the 

specific material requirements for crumpling 

on impact or absorbing crash 

energy in addition to functional requirements, 

there is a very high mechanical 

specification. 

At the moment, these characteristics 

are achieved with special alloys that 

often require heat treatment and straightening. 

This is carried out after the 

part is cast, later in the process. In some 

cases straightening requires expensive 

manual work. 

New alloys are constantly emerging 

that could deliver comparable or superior 

mechanical properties with reduced 

heat treatment requirement, or indeed, 

cut out the heat treatment process step 

altogether (see Figure 6). 

Alloys for structural components with 

high requirements in elongation and 

strength 

Of course, any new alloy system will 

need to be approved and verified for 

the specific application, but the potential 

for improved quality and reduced 

costs is clear (see Figure 7). Indeed, in 

this example, there is the potential to 

reduce costs by a further 10 %, on top 

of the thermal management savings 

achieved in step 1. 

Designing for weight saving 

The drive towards die-cast structural 

components is motivated by saving 

weight. Structural components cast in 

aluminum alloy today have an average 

wall-thickness of 2.5 mm, with material 

concentration around connection points 

and ejector marks. By contrast, with 

careful design of the part and the casting 

process, the same components can 

be produced with a wall width of just 

1.8 mm. This can deliver up to 20 % 

savings in overall weight. 

Of course, the level of achievable 

weight reduction is limited by structural 

integrity, which depends upon the loads 

and stresses on each part when in use, 

in a vehicle. Using the shock tower 

example, intelligent design could 

reduce the weight of by 10 %, from 

4,000 g to 3,600 g. 

As well as helping to meet the argument 

for die-casting based on weight 

reduction, this would further reduce production 

costs by 4 % (see Figure 8), whilst 

creating a more sustainable product. 

24

30.00 

25.00 

20.00 

15.00 

10.00 

5.00 

0.00 

25€ 




+ without HT & Straightening 


Metal costs 




Figure 7: Potential cost savings from new alloys. 

30.00 

25.00 

20.00 

15.00 

10.00 

5.00 

0.00 

22.5€ 




+ without HT & Straightening 

- 10% 

- 4% 

22.5€ 

+Light weight design 

(-10 % part weight) 


Metal costs 




Source: Bühler cost saving study 

Figure 8: Cost saving potential by light weight design. 

21.5€ 

of material, thus contributing to a sustainable 

value chain. 

An overall cost reduction of over 

23 % 

In this example, fine-tuning thermal 

management, introducing new alloys 

and redesigning the shock tower to 

optimize weight and production has 

reduced the unit cost of each part from 

28 to 21.50 euros, an overall cost reduction 

of just over 23 %. 

Crucially, that could be enough to 

make this an attractive proposition for 

C segment medium cars, opening up a 

lucrative volume market for die-casting 

foundries worldwide. 

A powerful argument for 

application-specific cost-reduction 

programs 

This paper describes a theoretical cost 

reduction program for a typical shock 

tower and makes a powerful argument 

for fine-tuning products and processes 

to reduce costs and improve quality. 

At Bühler, investment in Industry 4.0 

technology, AI, SmartCMS and world-class 

digital services like Predictive 

Analytics and Downtime Analysis are 

designed to enable customers to continually 

refine processes for ongoing 

improvement. 

But every part has unique characteristics. 

Every application has specific parameters. 

And every foundry sets up and 

approaches cells differently. To make 

application-specific cost-reduction programs 

work, it’s essential that car companies, 

OEMs, product designers, 

foundries and die-casting machine 

manufacturers all work closely together 

to achieve the break-throughs that will 

serve the automotive industry – and sustain 

the die-casting industry – for many 

years to come. 

Herman Jacob Roos, Structural Process 

Manager, Martin Lagler, Director Global 

Application Technology Die Casting, 

Bühler AG, Uzwil, Switzerland, and Luis 

Quintana, Application Technology Specialist, 

BuhlerPrince Inc., Holland, 

Michigan, US 

An award-winning example 

of weight reduction 

In 2018, the 1st prize at Euroguss for 

the optimized design of a casting, went 

to a part which incorporated a weight 

reduction of 19 % compared to the functionally 

identical part of the previous 

model [4]. This was achieved with a 

high-strength, highly flowable alloy in 

combination with a strength-optimized 

T6 heat treatment. The thin-walled 

design also saves a significant amount 

References: 

www.cpt-international.com 



Photo: ?? 

Light-weight castings can be 

joined by means of latest laser 

welding methods to manufacture 

highly loadable and economically 

efficient structural components. 

Castings for lightweight 

engineering 

Cast iron and aluminium alloys as alternatives for 

thin-section steel castings. 

Wolfgang Knothe, Franken Guss, Kitzingen 

The urgent call for light-weighting 

solutions in automotive engineering 

entails two key requirements: 

reliable and consistent material properties 

of the component, and a design suitable 

for the expected in-service stress 

load of the component. In other words, 

the service life of a component depends 

to a large extent on the component 

design. This is where casting technology 

comes in because here both the geometry 

of a component and the material 

properties evolve in one and the same 

process. Additionally, thanks to the high 

degree of process automation, large 

series production is assured. 

Steel casting has its limits, above all 

for economic reasons. Steel‘s very high 

melting and casting temperatures, its 

high shrinkage rates and the complexity 

of steel heat treatments are the main 

causes for this. The development of 

advanced materials, such as ductile iron 

and T6 aluminium alloys, has overcome 

these constraints. This does not mean 

that the importance of aluminium as 

the classical light-weighting material 

has decreased. While ductile iron and 

steel alloys have similar properties, the 

melting temperature of ductile iron is 

lower by 400 K, giving it excellent teeming 

properties. Meanwhile, a number 

of highly loaded structural parts which 

used to be exclusively made of steel 

have been replaced by ductile iron castings. 

Ductile iron castings are characterized 

by the following features: 

a b c 

Figure 1: Light-weight ductile iron castings. a) tubular cross member, b) differential cage, c) pressure plate. 

a b c 

Figure 2: Light-weight aluminium castings. a) sill plate, b) bearing bracket for front suspension, c) steering support. 

26

forming of the part and adjusting 

the material properties take place in 

a single process, 

> automatic molding lines use 100% 

recyclable quartz sands, 

> high yield, 

> easy, mechanized cutting off of the 

casting from the runner system, 

> low residual stresses in the as-cast 

condition, 

> adjustment of specific grades 

through targeted heat treatments, 

> good weldability, 

> possibility of producing components 

with complex functions. 

The successful manufacturing of structural 

components consisting of ductile 

iron castings and steel parts joined by 

welding opens up great potential for 

innovative light-weighting solutions. 

Production at Franken Guss 

The iron foundry can produce castings 

from all types of cast iron, i.e. ductile 

iron, grey cast iron and compacted graphite 

cast iron. It is equipped with three 

mechanized and automated molding 

lines. With this highly advanced equipment, 

near-net-shape geometries can 

be produced and the implemented data 

Figure 3: Before new components are produced in series, Franken Guss prints 

3-D-prototypes. 

infrastructure assures stable production 

processes. Automated DISA molding 

lines operate in conjunction with 

laser-controlled “Pouromat” pouring 

equipment. 

The main alloys used in the aluminium 

foundry are EN-AC-AlSi9Cu3 (Fe), 

EN-AC- AlSi 10Mg (Fe) and EN-AC-AlSi 

12 (Cu). Twelve pressure casting cells are 

in place, operating in conjunction with 

robots which pick up the castings from 

the molds and transfer them via the 

flash trimming press to the transport 

unit. The biggest casting cell has a 

Industrial Autumn 

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a 

c 

b 

Figure 4: Development of a 

reinforced member for a 

driver’s cabin. a) frame 

head with member for driver’s 

cabin, b) initial concept, 

c) current geometry of 

the ductile iron cast component 

(weight saving: 15%). 

Figure 5: New design of the 

front suspension bracket 

(grade: EN-AC-Al-Si10Mg 

T6) (weight saving: 30%) 

locking force of 2,000 t. Heat treatments, 

as T 5 or T 6, for example, are 

possible without restriction because the 

mold filling technique reliably prevents 

gas porosity in the castings. 

The product portfolio for both cast 

iron and aluminium comprises a wide 

range of different large-series-produced 

castings which comply with the latest 

light-weighting requirements (Figures 1 

and 2). Prototypes are produced by 

means of a state-of-the-art laser sintering 

system, which produces a 3-D printed 

prototype ready to the installed 

(Figure 3). 

Light-weighting concept 

In automotive engineering, the design 

of structural vehicle parts is largely 

determined by the static and the dynamic 

load case, and, in particular, the 

crash performance. Only the static load 

case can be assessed by means of quasi-static 

parameters, such as tensile 

strength Rm, yield strength Rp or elongation 

A5. The dynamically determined 

material parameters, such as the supportable 

medium stress amplitude, 

depend on the notch factor of the designed 

component. As the notch sensitivity 

increases with increasing material 

strength, high-strength materials are 

unsuitable for light-weighting designs. 

The decisive parameter is 

the modulus of elasticity! 

The modulus of elasticity (Young’s 

modulus) depends on the graphite 

form, i.e. compacted graphite iron, grey 

cast iron or ductile iron. However, for 

the graphite forms in the compact to 

spherical range, the modulus is more or 

less the same independent of the 

strength of the material. Instead, for 

light-weighting applications, the deformation 

behaviour is more important. 

This refers to the supporting effect, for 

example, or the use of anisotropy to 

evaluate the fatigue stress behaviour. 

Fusion welding 

with 

filler material 

Laser Electric arc Gas Fusion 

welding 

Compression welding 

without 

filler material 

Magnetic 

Arc 

welding 

Capacitor 

discharge 

welding 

Figure 6: Applicable welding methods for joining (light-weight) castings with steel elements. 

Examples of light-weighting 

concepts 

Its excellent manufacturing facilities 

and materials competence enable Franken 

Guss to determine in-house 

whether cast iron or aluminium would 

be the best suitable material for the 

application on hand and to develop 

application concepts by themselves. 

Building on these capabilities, Franken 

Guss has evolved from a service provider 

to a development partner for its 

customers. This includes simulations 

using state-of-the-art techniques and 

28

a 

Nuremberg, Germany 

14 –16.1.2020 

b 

International Trade Fair for Die Casting: 

Technology, Processes, Products 

Figure 7: Development 

of a tubular cross member 

incorporating a 

ductile iron casting as 

shaft with welded on 

flanges made of steel. 

a) welding concept, b) 

compression welding of the parts using the MagnetArc process. 

the analysis of material behaviour under different load cases. 

Various weight-optimized series parts, such as the ductile iron 

reinforced member for a driver‘s cabin (Figure 4) or a newly 

designed suspension bracket made of the aluminium alloy 

EN-AC-Al- Si10Mg T6 (Figure 5) testify to the practical usefulness 

of the concepts. 

Light-weight engineering by means of structural 

welding 

Structural welding (Figure 6) is used to join castings with formed 

steel components. The most common methods are fusion 

and compression welding. These welding techniques are 

widely used in the manufacturing of differential cases with a 

ring gear (Figure 7), which include a welded joint between 

ductile cast iron and steel. 

FUTURE 

CASTING 

IDEAS 

Visit Europe’s 

leading trade fair! 

euroguss.com 

Bottom line 

> By using the design flexibility of casting technology, components 

of a much higher loadability can be designed 

than – allegedly – achievable by an increase in material 

strength. 

> The application of methods of bionics are recommended 

for castings only. 

> Structural welding enhances the functionality and promotes 

light-weighting by joining ductile iron castings and formed 

steel components. 

> Forging and casting are complementary forming processes 

which give fresh impetus for new light-weight, highly 

loadable and economically efficient structural components. 

About Franken Guss 

Franken Guss is a medium-sized company and, together with 

Sachsen Guss in the German federal state of Saxony, part of 

JORA Holding. The foundry has a more than 90-year-history in 

Kitzingen, Germany. 

The contents of this article have already been dealt with in 

a paper presented at the IFU Congress NE-MU on 14/15 May 

2019. 

Dr.-Ing. Wolfgang Knothe, Development Iron Casting, 

Franken Guss GmbH & Co. 

Honorary sponsors 

VDD Verband Deutscher 

Druckgießereien, Düsseldorf 

CEMAFON, Frankfurt am Main 

We’ll be pleased to help you! 

NürnbergMesse GmbH 

T +49 9 11 86 06-49 16 

visitorservice@nuernbergmesse.de 


RECYCLING 

Photo: Fagus 

Metal is recovered from residues in four melting furnaces. Photos: Siegfried Jacob Metallwerke GmbH & Co. KG 

Recycling – certainly safely! 

The GreCon spark extinguishing system sees to a safe production at 

Siegfried Jacob Metal Works 

by Denis Sauerwald, Alfeld 

Recycling instead of scrapping 

With the recycling of basic materials 

becoming more and more important, 

the demands on recycling companies 

are also increasing. Coping with continuously 

growing quantities requires a 

high availability of the production facilities. 

To ensure the highest possible 

availability, it is necessary to protect the 

facilities at risk against loss of production 

caused by fire. Fire risks are lurking 

in numerous phases of recycling processes. 

Foreign objects, process heat or 

machine parts can cause sparks, glowing 

embers or overheating which may 

lead to serious fires or explosions in 

shredders, belt conveyors or extraction 

systems. 

In the field of recycling, Siegfried 

Jacob Metal Works have been specialized 

in the recovery of metals for more 

than six decades. The company, located 

in Ennepetal, Germany, is known as a 

reliable supplier of high-quality 

secondary raw materials from aluminium 

to zinc. Founded as a scrap metal 

merchant in 1953, the company 

developed into one of the major metal 

recycling companies in Europe in the 

past 60 years. Today, several thousand 

tons of metal are recovered per year at 

10 sites with about 1,000 employees. 

The site in Ennepetal, Germany, produces several thousand tons of secondary raw materials 

in 33 halls. 

Metal recycling – a hot matter 

The conditioning processes reach from 

classic sorting via pyrometallurgy up to 

hydrometallurgy. Especially in pyrometallurgical 

processes, there is a permanent 

risk of spark flight. Pyrometallurgical 

recycling simplified means that scrap 

metal and other metallic residues are 

melted at high temperatures in a furnace 

and processed to customer-specific 

alloys. Siegfried Jacob Metal Works produce 

up to 10,000 tons of metal out of 

scrap metal per year in four melting furnaces, 

having a capacity of several tons 

each. There is a permanent risk that 

sparks or glowing particles reach the 

filters via the extraction system where 

they would meet an explosive dust concentration 

and can cause devastating 

fires or explosions. Siegfried Jacob 

Metal Works want to reliably prevent 

such damaging events. 

30

An automatic extinguishing device is mounted 

directly before the filter and eliminates 

risks of fire before they can cause damage. 

Highly sensitive GreCon spark detectors, type FM 1/8, are mounted on the exhaust duct 

and detect sparks and glowing particles. 

Protected against sparks 

for many years 

Siegfried Jacob Metal Works already 

protected their filters with automatic 

spark detection and extinguishment in 

2001. “The spark extinguishing system 

makes us feel safe that no sparks can 

reach the filters”, says Dr. Joachim 

Lüning, Factory Manager. The GreCon 

spark extinguishing system has been in 

operation for 15 years. The recycling 

company has the system, that is working 

very reliably, serviced on a regular 

basis by the GreCon service team – 

being 70 strong. Maintenance comprises 

numerous function tests of the system, 

the cleaning of spark detectors 

and extinguishing devices as well as 

software updates of the control console, 

if necessary. 

Prepared for the future 

Siegfried Jacob Metal Works intend to 

continue their growth strategy. A 

modern wind energy plant is planned 

for power supply. Future expansions of 

the production capacity require new 

extraction systems. In preparation of 

this, the control console of the spark 

extinguishing system was updated to 

the latest generation. The new control 

console (type CC 5016) is easier to operate 

and provides a graded alarm function 

thanks to programmable alarm 

thresholds as well as the option for possible 

extensions. 

Denis Sauerwald, Fagus-GreCon Greten 

GmbH & Co. KG, Alfeld, Germany 

We are looking forward to your 

visit at EUROGUSS 2020 in 

Nuremberg, January 14-16, 

hall 9, booth 9-269 

Competence in 

Shot Blast Technology 

We offer a complete service in surface preparation technology, 

not just as machine designers and manufacturers. 

Our emphasis is on providing reliable service on: 

• Wear and Spare Parts 

• Repair and (remote) maintenance 

• Inspection and process advice 

• Machine upgrades and performance 

enhancement 

• Upgraded used machines 

AGTOS 

Gesellschaft für technische Oberflächensysteme mbH 

Gutenbergstraße 14 · D-48282 Emsdetten 

Tel. +49(0)2572 96026-0 · info@agtos.de 

www.agtos.com 

272-10/19-4c-GB 


FETTLING AND FINISHING 

Automated blasting of 

aluminium castings 

Delivery of new workpiece 

boxes to the blasting cell. 

Two leading manufacturers in their respective sectors have decided to launch a joint 

project in the area of surface technology. The result of this is an automated blasting 

cell for mass-produced castings. 

Ulf Kapitza, Emsdetten 

Photos: AGTOS 

Around 475 personnel are employed 

at the SEW Usocome plant 

in Forbach, France. This facility 

is the aluminium component competence 

centre for the SEW Group. The 

SEW Group is a family enterprise operating 

all over the world. SEW is a globally 

known name in the area of drive 

systems. 

A new AGTOS rubber belt tumble 

blast machine was installed here 

recently for post-processing of covers 

for terminal boxes and gearboxes. 

AGTOS with its headquarters in Emsdetten, 

Germany, is a manufacturer of shot 

blasting machinery operating on an 

international level. In addition to reliable, 

high-performance blasting technology, 

the company has extensive knowhow 

in the area of workpiece handling 

and process optimization. 

The blasting objective is the deburring 

of parts and creation of a uniform 

surface. Parts are washed and then 

painted following blasting. 

Situation analysis 

Workpieces (covers for terminal boxes 

and gearboxes) were processed in a 

rubber belt tumble blast machine. This 

was manually loaded and unloaded 

and, as a consequence, had a longer 

cycle time. The number and variety of 

parts had also grown over the years, 

meaning that the capacity could no longer 

be achieved. There was evidently a 

need for a machine delivering a higher 

level of performance. 

The effort involved in handling parts 

was too great. As the blasting machine 

represented a bottleneck, it was necessary 

to provide interim storage for the 

finished castings before processing 

them in the blasting machine. This 

required space, time and labour. 

32

Romain Zorzi, Project 

Manager for 

New Processes. 

Plan view of the 

blasting cell. 

View of the blasting cell, with robot, blasting machine 

and conveyors. 

During planning, an idea matured 

with regard to time integration of the 

new machine in the process. The storage 

between casting and blasting was to be 

avoided, which entailed designing the 

machine so that it could blast quicker 

than new parts emerge from production. 

“Employees were to be relieved of 

tasks that do not directly add value to 

the workpieces”, says Romain Zorzi, Project 

Manager for New Processes. 

Surface technology solution 

The tip to consider AGTOS as a blasting 

technology provider came from the 

blasting abrasive manufacturer. Workpieces 

were initially blasted in the 

AGTOS plant and that of another customer 

to test performance. The abrasive 

and machine were optimally coordinated 

during this, with the results being 

so positive and the cover of the workpieces 

so good that it was decided to 

purchase the new blasting machine 

from AGTOS. 

This was followed by a phase involving 

concrete tests and calculations, 

with technicians from both companies 

working closely together to realise 

these. The solution is really impressive. 

In terms of design, manual loading and 

unloading of the blasting machine was 

initially retained. The elimination of 

interim storage on its own was a decisive 

advantage. The new blasting 

machine has a lower cycle time and is 

more efficient in terms of its overall 

blasting technology. 

Prior to commencing installation, 

individual installation and implementation 

steps were defined during the 

course of a meeting. It became clear 

that positioning and installation of the 

assemblies delivered on schedule at the 

site posed a logistical challenge. Several 

suppliers and SEW needed to work 

hand in hand in this respect (blasting 

machine, crane, lift platform, energy, 

pneumatics). A major site developed 

during installation. The blasting 

machine was set up and connected 

while adjacent machinery continued 

operating. A complete noise reduction 

enclosure was simultaneously constructed. 

“The machine has been operating 

without any problems since installation, 

and the cycle time is perfect”, confirms 

Romain Zorzi. 

Following installation of the 

machine, operation was changed from 

manual to robot loading. This is where 

technicians from SEW and AGTOS truly 

worked hand in hand. In addition, it 

was necessary to cover the range of 

parts to be processed with a single blasting 

program. This task was solved by 

AGTOS. Quality and the cycle time for 

workpieces were defined at the outset 

in the specification, and optimum blas- 


FETTLING AND FINISHING 

„You could say that the process 

has been simplified, 

because handling has been 

drastically reduced“ 

Process sequence in 

the blasting cell 

Several workpiece boxes are delivered 

by forklift to the blasting cell and placed 

on a roller conveyor there. The 

robot picks up the boxes individually 

and places them in a feeding system. 

This tips the workpieces into the opened 

trough on the blasting machine. The 

rubber belt moves after the door closes 

and mixes the parts, ensuring that turning 

of the workpieces is gentle. Maintaining 

low gap dimensions in the blasting 

machine interior means that even 

very small parts can be blasted. 

The high-performance turbine located 

above blasts abrasive at the workpieces, 

reaching all surfaces as a result 

of the turning action. The abrasive is 

collected beneath the machine, precleaned 

and conveyed to the upper part of 

the machine. Further separation of dust 

and undersized particles from the abrasive 

is achieved here through an air 

stream. A wet filter unit creates the 

required negative pressure for this purpose. 

The cleaned abrasive is then made 

available again to the high-performance 

turbines and, consequently, the 

complete cycle. 

Following blasting, the door opens 

and the rubber belt changes its direction 

of travel. The workpieces are 

gently directed as a result towards a 

vibrating channel that takes them to a 

conveyor belt which leads to the box 

filling system. The filled box is picked 

up again by the robot and placed in a 

removal area. The box in turn is taken 

from here by forklift to the next processing 

step. 

Workpiece feeding channel after the blasting process. 

ting parameters were determined 

through testing. 

Today, the workpieces are only 

deposited in transport boxes in front of 

the blasting cell by the forklift driver, 

and finished parts are collected and 

conveyed away. Processing in itself is 

completely automatic. “You could say 

that the process has been simplified, 

because handling has been drastically 

reduced”, says Zorzi. 

Following blasting, the workpieces 

are returned to the same transport 

boxes they were delivered in. This 

enhances the transparency of the process, 

and certification of quality is simplified. 

Competence in shot 

blasting technology 

AGTOS blast machines are distinguished 

by a high degree of robustness, a long 

service life and maintenance-friendliness. 

The high-performance turbines 

are designed to ensure extremely low 

wear, even in the severest of operating 

conditions. Moreover, they are capable 

of a high abrasive shot flow rate while 

requiring the same amount of energy as 

other turbines. They are extremely efficient 

as a result. The blasting chamber 

itself is lined with replaceable, highly 

wear-resistant manganese and tool 

steel plates. 

The company’s customers always 

emphasis the high level of maintenance-friendliness 

of these blasting machines. 

The entire machine is not only designed 

for long-term operation, but 

optimized for maintenance and the 

replacement of spare and wear parts. 

For example, AGTOS high-performance 

turbines are equipped with easily replaceable 

turbine blades. 

Other servicing work such as replacement 

of the rubber belt can be 

34

Workpieces before and after blasting. 

quickly realised, thanks to a well-designed 

maintenance system. 

AGTOS was founded in 2001 in 

Emsdetten by employees with experience 

in this area. Now, more than 160 

employees are employed at the two 

sites. In Emsdetten, the headquarters of 

the company, the concepts are 

developed and the turbine-wheel blasting 

machines designed. The manufacturing 

site is located in the Polish city of 

Konin, near Poznań. 

The constant focus on the requirements 

of the customers has lead to the 

fact that the company is regarded as a 

specialist in the design and manufacture 

of turbine-wheel blasting equipment 

for roughing, cleaning, removing 

rust, descaling and hardening. Therefore 

customers on all five continents 

work with the shot-blasting machines 

from AGTOS. 

In addition to new shot blasting 

machinery, AGTOS also offers used blasting 

systems. This is an advantage for 

customers who need a blasting machine 

at very short notice or only wish to use 

it temporarily. 

The abrasive used in shot blasting 

machines not only affects workpieces 

surfaces, as the abrasive impact is also 

noticeable in the blasting machines 

themselves. This is why service, meaning 

stocking and delivery and the installation 

of spare and wear parts, plays an 

important role. Added to this are maintenance, 

repair and modernization 

work on machines from other manufacturers 

which are at all times realized by 

experienced skilled personnel. 

www.agtos.de 

VIDEO BORESCOPES 

Hawkeye ® Pro 

V2 Video Borescope 

Price Reduction! 

Prices now starting at 

$ 

5995! 

Offer good until 

December 31, 2019 

Ask for V25995 

In anticipation of 

introducing new 

videoscope technology 

in 2020, which will retail 

starting at $9995, we are 

now offering our current 

Hawkeye V2 Videoscopes 

starting at only $5995… a 

tremendous value for the 

scope that has been the 

industry leader. 

Ulf Kapitza, Sales + Marketing Manager, 

AGTOS Gesellschaft für technische 

Oberflächensysteme mbH, Emsdetten 

gradientlens.com 800.536.0790 

MADE IN 

USA

LOGISTICS 

Forklift fleet keeps 

the castings moving 

The compact RX 70 diesel forklift combines 

dynamic maneuverability with state-of-theart 

hybrid drive control for particularly low 

consumption 

The industrial trucks at Fondium’s production works in Singen have been brought up-todate 

by forklift expert Still to enable the company to continue asserting itself in the 

intense competition for automotive castings. Still’s FleetManager is an important component 

of this fleet modernization. All in all, a considerably higher level of fleet operational 

readiness has been achieved despite a reduction from 136 to 119 vehicles. 

Gerd Knehr, Reutlingen 

Photos: Still 

This downsizing of the fleet effectively 

cuts maintenance and repair 

costs. 23 maintenance-free lithium-ion 

warehouse vehicles are now 

also stationed directly in the departments 

with their own charging points 

– eliminating both the long paths to the 

former central charging station and 

supplementary substitute wet-cell batteries. 

Prepared for the future 

Since the site at Hohentwiel in Singen 

was founded in 1895, Georg-Fischer 

(GF) Automobilguss has become a leading 

company for heavy-duty cast-iron 

vehicle components. Examples include 

brake calipers for the well-known company 

Knorr-Bremse, as well as wheel 

hubs and steering knuckles for truck 

producers such as Daimler, MAN, Renault, 

DAF or Volvo. 

The GF sites in Singen and in Mettmann 

near Düsseldorf achieved sales of 

550 million euros with about 2,000 

employees in 2018. The Singen works 

mainly manufactures vehicle parts for 

trucks, while car components are principally 

produced in Mettmann. Both 

foundries were taken over by the Fondium 

Group at the end of last year, following 

restructuring of the product 

portfolio of the GF Group, based in 

36

Safety has top priority 

at Fondium. All front 

loaders are equipped 

with the Safety-Light 

4Plus from Still. 

With their own charg ing 

points, the li-ion industrial 

trucks are immediately 

available in the 

departments – eliminating 

long paths and 

long waiting times for 

the batteries to charge. 

The RX 70 is a key vehicle for internal 

transports in the melting shop. 

Schaffhausen, Switzerland. GF and Fondium, 

however, have continued to work 

together in some segments. Manuel 

Veser, Manager of Fondium’s Logistics 

Center in Singen, is confident: “With 

our production capacity and sales of 

about 180,000 tonnes per year we can 

produce large serial numbers – with a 

total of more than 12,500,000 ready-to-install 

castings – thanks to our 

computer-supported design and manufacture.” 

FleetManager keeps 

everything in view 

Production and logistical processes, as 

well as the production plants at the Singen 

works, are regularly modernized. 

Whereby a fleet of forklifts adapted to 

the needs of production is a very 

important factor. All vehicles have GPRS 

radio data transmission and an RFID 

chip for drive authorization. Mathis 

Märgner, responsible for fleet maintenance 

in Singen, stresses that “If the 

defined acceleration value is exceeded 

during a forklift operation the vehicle 

can be forced into creep mode, depending 

on the setting of the acceleration 

sensor in the accident recorder. This 

reaction can not only be selected to 

prevent collisions, but also if the vehicle 

moves too quickly over uneven surfaces.” 

Manuel Veser adds that “We have 

been logging collisions for several years 

using the FleetManager from Still. 

Together with Still we have analyzed 

pictures of the damage to both vehicles 

and the operating materials transported 

and have been able to determine 

and eliminate potential sources of risk 

on the drive paths at the works. The 

drive behavior of the forklift drivers has 

improved enormously due to annual 

training and the filling in of operation 

control books, in coordination with the 

Works Council. As a result, the accident 

rate has fallen by about 80 percent.” 

The transparent vehicle biography 

also shows whether particular forklifts 

are working to capacity while other 

vehicles have already done too many 

operating hours. This form of recording 

minimizes the risk of further maintenance 

and servicing costs due to 

non-compliance with the contractually 

agreed level of operating hours. Moreover, 

as a result of standardization and 

fleet-oriented optimizations, the 

forklifts can be exchanged between the 

works departments more easily. The 

fleet is therefore better utilized. 

State of the art: li-ion 

warehouse technology 

increases availability 

For the first time, 23 warehouse trucks 

with lithium-ion batteries have been 

stationed in the individual departments. 

The advantages are clear: separate charging 

devices in the departments mean 

that the EXV 20 high-lift pallet trucks 

from Still are now available at any time. 

Mathis Märgner finds the new technology 

convincing: “The most important 

reason was the time savings achieved by 

cutting out the long path to the central 

charging stations and the long charging 

times required there by the wet-cell batteries. 

With their own charging stations 

in the departments, we can recharge the 

li-ion trucks at short notice during breaks. 

The li-ion batteries reach 50 percent 

of their charge capacity after only 30 

minutes, whereby the service life is not 

impaired by the rapid interim charging. 

This removes the need for replacement 

batteries and long charging cycles, as 

well as the complicated maintenance of 

the wet-cell batteries in the dusty 


LOGISTICS 

environment.” Alexander Heimburger, 

Sales Manager at the Still branch in Freiburg 

and in charge of the forklift fleet 

project confirms that “These optimization 

potentials came up during the 

intensive consultation sessions. In addition, 

the service life of the lead-acid cells 

was only four years due to maintenance 

being carried out in the dusty foundry 

environment and because of the necessary 

interim charging. The wet-cell batteries 

of the industrial trucks also lose 

part of their capacity when the vehicles 

are used infrequently and irregularly. On 

the other hand, the constant voltage of 

the maintenance-free li-ion batteries, i.e. 

full performance during extremely long 

service lives, is impressive. Depending on 

the vehicle’s equipment and demands, 

use of li-ion technology can be amortized 

after just one or two years.” 

The hydraulic system of the RX 70’s tilting device is protected against flying sparks and 

falling casting residues. 

Forklift fleet fits as if tailor-made 

During the last four years, about 50 RX 

60 electric forklift trucks with a load 

capacity of from 2.5 to 5.0 tonnes have 

been in use for approximately 15,000 

hours each without any significant failures. 

With its heavy castings, the 

foundry is a classic deployment location 

for forklift transport vehicles. With 50 

different load carriers available, the RX 

60 ‘endurance runners’ are responsible 

for most of the material flow within the 

works. “Safety has top priority at Fondium. 

The last time we changed the 

vehicles we increased the protection for 

the roof bars, added a protective grid 

to the cabin roofs, and mounted skirting 

boards on the driver’s cabin in response 

to the collisions. In addition, all 

the front-loaders were equipped with 

Safety Light 4Plus because pedestrians 

notice the forklifts quicker and have 

more time to react thanks to the direction-indicating 

function of the sequential 

illumination, made up of four light 

points,” notes Sascha Heim, the Still 

salesman responsible for Fondium. 

Intensive planning and vehicle configuration 

is necessary in advance of such 

optimizations. Together with the managers 

of the various departments, the 

foundry’s logistics team evaluated the 

results of such analyses in detail. 

Manuel Veser: “In many intensive discussions 

we found again and again that 

an optimum composition of our fleet 

would only be possible if the relevant 

areas in the works departments collaborated. 

Together with Still, and exploiting 

Mathis Märgner’s many years of 

experience in customized forklift fleets, 

we were able to implement the configurations 

of the versatile vehicles in 

many work steps so that we could ultimately 

order a forklift fleet from Still 

that was customized for our needs.” 

When the going gets tough 

Five robust RX 70-50600 vehicles are 

used for the heavy transports in the 

melting shop. The diesel forklifts from 

Still combine dynamic maneuverability 

with modern hybrid drive control for 

particularly low consumption. Over the 

years a total of 18 special modifications 

have been made to the compact diesel 

forklifts to meet the tough demands of 

the foundry. So, for example, the windscreen 

is a non-convex heat protection 

screen mounted in a steel frame. The 

wings are made of metal, and the headlights 

and tilt cylinder are equipped 

with a metal cage to protect the front 

wheels against flying sparks. An additional 

heat protection pane has been 

added above the cabin pane on the 

right of the driver’s cabin. 

The hydraulic system of the RX 70 

tilting device attachment is also protected 

against flying sparks and falling casting 

residues. The tilt mechanism can be 

safely operated from the driver’s cabin 

without the need to leave it. 

Another example is the customized 

RX 60-25 swivel-seat forklift. Three of 

these forklift variants are used for the 

long transport routes. When reversing, 

an ergonomic sitting position is provided 

by 45-degree rotation of the driver’s 

seat and duplicate acceleration 

and brake pedals. So internal works 

transports can easily be carried out driving 

backwards. Reversing is also safer 

during transport thanks to the enlarged 

field of view. 

Well-organized service 

and maintenance 

Two Still mechanics are constantly available 

at the customer workshop in two 

shifts from 6 a.m. to 6 p.m. During the 

remaining time and at weekends, a service 

technician from Still can be at the 

works within two hours thanks to the 

agreed on-call service. Additional 

standby vehicles are also available for 

particularly important forklifts. 

“Together with the works logistics 

team, we have set up an efficient 

on-site service as part of our shop floor 

management. Whereby all work-specific 

information is comprehensibly shown 

on a board so we can quickly gain an 

overview of the order processes and 

tasks in the workshop. Weekly feedback 

meetings complement this efficient 

organization,” explains Alexander 

Heimburger. The immediate result is the 

extremely high level of industrial truck 

availability of about 90 percent. 

Summary 

Robust, ergonomic, maneuverable and 

comfortably equipped forklifts are 

required to handle the extreme stresses 

with the uneven surfaces in the dusty 

environment of the foundry. Manuel 

Veser sums up: “The basis for the good 

collaboration with Still is the RX 60 

‘endurance runner’. We have had very 

positive results with these reliable topclass 

forklifts over many years. In addition, 

extensive optimization potentials 

have been opened up with the Still 

FleetManager and the maintenance-free 

li-ion warehouse trucks.” 

www.fondium.eu 

Redaktionsbüro Gerd Knehr, 

Gerd Knehr, Reutlingen 

38

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COMPANY 

Photos: ROBERT PITEREK/BDG, FRECH 

70 years is not enough 

The Oskar Frech Group, based in Schorndorf, will be 70 years old this year. The familyrun 

company represents the ‘Made in Germany’ brand worldwide with inventiveness 

and entrepreneurial courage, successfully competing against large corporate groups. 

A Swabian success story that still holds many surprises in store for the future. 

Robert Piterek, German Foundry Association, Düsseldorf 

Those in the sector considering the 

purchase of die-casting equipment 

simply cannot ignore 

machine constructor Oskar Frech from 

Schorndorf. The machinery produced by 

this Swabian family company, which will 

be 70 years old this year, is found in 

numerous die-casting foundries in Germany 

and elsewhere. About 6,000 

machines from the works halls in Weiler 

and Plüderhausen in Germany, and 

Fengxiang near Shanghai in China, have 

been delivered to customers in 78 countries 

over the years. Their estimated 

output: many billion castings made of 

numerous materials – from zinc window 

and sanitary fittings, through power 

tools made of magnesium, to aluminum 

structural parts and gearbox housings. 

In recent decades, the efficient and 

increasingly networked machines and 

plants have provided numerous companies 

all over the world with 

indispensable equipment for producing 

high-quality castings – enabling them to 

earn good money. 

Management with an alert eye 

“Frech is the only die-casting plant constructor 

worldwide that can claim to be 

40

Plant production in 

Plüderhausen. More 

than 150 machines 

are assembled here 

every year. 

As its CEO, Dr. Ioannis 

Ioannidis has 

already been determining 

the destiny 

of the company for 

16 years and is also 

active in associations 

and with the 

press. 

‘Made in Germany’ and is 100 percent 

family-owned,” stresses Dr. Ioannis 

Ioannidis, President and CEO of the 

Frech Group, in a resonant voice that 

seems to give this sentence even greater 

significance. “Our competitors are 

mainly members of large corporate 

groups,” he adds after a brief pause, 

referring to companies such as Bühler 

Druckguss, IDRA and Italpresse, among 

others. 

Dr. Ioannidis has now been running 

the company for 16 years. During this 

time he has successfully integrated the 

cold-chamber die-casting machines 

division of the company Müller Weingarten 

into the group, kept the company 

operating healthily through the 

economic crisis, and ensured consistent 

continuity of the internationalization 

process initiated by Wolfgang Frech, 

son of the founder. The CEO leads the 

company with an alert eye on the political 

and technological developments 

of the time. Under his leadership, two 

important current megatrends in the 

sector are being worked on and molded 

into interesting business concepts: 

digitalization and additive manufacturing. 

At the same time, he has reacted 

to the constantly rising demand for the 

company’s wares with expanded production 

facilities and new works, 

accompanying Frech’s business 

development as President of CEMAFON 

(the European Foundry Equipment 

Suppliers’ Association) as well as being 

Chairman of the Executive Board of 

the VDMA Metallurgy engineering 

association. The latest VDMA success 

has been the introduction of the new 

OPC UA interface standard, which 

could represent an important step forward 

in digitalization among foundry 

equipment suppliers. Dr. Ioannidis, 

however, is also concerned about matters 

that reach far beyond his company’s 

interests – most recently in an ARD 

television interview about SMEs, a 

topic close to the heart of the company 

director. He wants to see more support 

for SMEs in the form of funding for 

innovations and changes in tax and 

inheritance law. “It is five past twelve,” 

he says, using the interview to clearly 

express the need for action. 

As CEO, he leads a healthy company 

with about 800 employees worldwide, 

annual sales of 160 million euros, and 

an output of about 150 hot- and 

cold-chamber die-casting machines per 

year. The company has blossomed under 

his management: Dr. Ioannidis can look 

back on average annual growth of 12 

percent during recent years. The takeover 

of the former cold-chamber competitor 

Müller-Weingarten has played an 

important role in this remarkable 

growth. This acquisition has made Frech 

equipment an integral component of 

the machinery of OEMs and Tier 1 suppliers. 

Plants with cold-chamber technology 

now contribute annual sales that 

far exceed 50 million euros. 

The order books are full 

A change of scene to the Plüderhausen 

works, where every day 80 to 100 technicians 

work on the assembly of machines 

with clamping forces of 20 to 4,600 tonnes. 

The large machines are mainly destined 

for OEMs such as Peugeot, Mercedes, 

Audi, Volkswagen and Renault, but 

also Tier 1 companies like Trimet in 

Essen, the AE Group, Faist and others. 

With the help of a hall crane, some 

men in overalls are transporting a complete 

clamping unit to the base frame 

of an unfinished machine, while others 


COMPANY 

are working on the interiors of machines 

in a more advanced state. An enormous, 

almost finished, cold-chamber 

die-casting plant can be seen at the 

front of the hall. The four horizontal 

pillars on which the tool moves – and, 

during operation, closes the mold cavity 

for every shot and reopens it for removal 

– now each have the dimensions of 

streetlamps and a silvery sheen. Elsewhere 

in the hall, components of clamping 

units, base frames, as well as injection 

& pouring units are being put 

together to form modules. Hydraulic 

hoses in various designs – which the 

men in the Frech overalls collect centrally 

for installation in the numerous 

machine types – hang on a Kanban 

frame. Production follows a clear plan: 

one die-casting machine is constructed 

here in a three-day cycle – from putting 

together the individual modules, to 

acceptance and preparation for 

dispatch. 

The order books are currently full 

and, according to Dr. Ioannidis, the 

company is well equipped to deal with 

any economic developments. But why 

has this Swabian specialist in die-casting 

equipment been so successful? 

A die-casting plant is lifted into 

an enormous spraying chamber 

for coating. 

Louis Braun (left), Market Development 

and Sales, Cold-Chamber 

Die-Casting Machines with 

Norman Klare, Manager of 

Sales, Services and After-Sales. 

Innovation is the key to success 

The machine constructor has shaped 

die-casting technology in recent decades 

with a steady stream of fresh innovations: 

it launched the first fully electric 

zinc die-casting machine in 1999. 

“Both the clamping and the casting 

axles were electric,” recalls Louis Braun, 

who is responsible at Frech for market 

development and sales of cold-chamber 

die-casting machines. The problem with 

the extremely energy-efficient plants, 

however, was the price (which was, 

naturally, higher) so the machine ultimately 

failed to assert itself. The first 

hybrid plant with an electric casting 

axle and a hydraulic clamping axle was 

placed on the market in 2006. The system 

is rapid, powerful, quiet and economical. 

There are also, however, technologies 

that Frech, unlike its competitors, 

is not involved in. One example is the 

two-plate clamping unit of cold-chamber 

die-casting machines, where the 

clamping system is locked hydraulically 

with cylinders instead of with a mechanical 

toggle lever. “We have always 

used three-plate technology to provide 

a stable and easy-to-maintain clamping 

unit. Die casting is subject to extreme 

process conditions. A toggle lever, such 

as that used with three-plate technology, 

is more robust in such situations 

than a pressure box – which is highly 

maintenance-intensive,” explains 

Braun. 

One of the company’s biggest innovations, 

however, is yet to come: the 

aluminum hot-chamber die-casting 

machine. Up to now, aluminum could 

only be cast using the cold-chamber 

process due to its metallurgical properties. 

This should change in the foreseeable 

future. “Feeding of the molten 

metal in the cold-chamber process takes 

place via an external container. Then 

the liquid aluminum melt is emptied 

into a press chamber before shooting,” 

explains Braun. With the hot-chamber 

system, on the other hand, the pouring 

flasks are integrated in the plant – with 

advantages for economic efficiency and 

casting quality: considerably less re-melt 

material, significantly lower energy 

consumption with shorter cycle times. 

The hot-chamber plant for aluminum, 

exhibited as a study for the first time at 

GIFA in 2011, has now almost reached 

technical maturity. 

Time to tinker about 

That this technological breakthrough is 

nearing completion 70 years after the 

company was founded is also the result 

of Frech’s commitment to intensive 

research. More than seven percent of 

sales proceeds flow into research and 

development. Universities and institutes, 

such as Aalen University, Kassel University, 

RWTH Aachen University, and 

42

Technician carrying out precision 

work. The pressure tanks for the 

hydraulics in three vertical cylindrical 

piston accumulators can be seen in 

the background, on the left. 

the Institute for Applied Nanotechnology 

in Karlsruhe also receive support. 

“One must give the researchers time to 

tinker about, and retain good people 

by paying them properly,” Dr. Ioannidis 

points out the high status of research at 

Frech. 

Research, however, is not only carried 

out on die-casting technology, but 

Research work on a 

die-casting plant in 

Schorndorf-Weiler. 

The new hot-chamber 

die-casting machine for 

aluminum, soon to be 

available on the market 

also regarding data capture – involving, 

among other things, cycle times, material 

compositions, and the time of production. 

“We have 6,000 die-casting 

machines in the field and most of them 

are in productive operation. This quantity 

of applications in the background 

allows us to create meaningful linkages,” 

affirms Dr. Ioannidis and adds: 

“For us it is about a sensible processing 

of big data to smart data.” 

At the GIFA, Frech presented its 

new smartfoundry.solutions in a large 

hemisphere. The networked die-casting 

foundry shown there visualizes all 

the production parameters comprehensibly 

in graphic form, enabling 

comparison with older data as well as 

data from other machines. And, in 

future, it will be possible to predict 

faults and determine maintenance 

dates. In addition to the plants (the 

hardware), digital products require 

software. The focus in the company is 

thus shifting even farther towards services, 

which now already make up 25 

percent of sales. An application from 

the augmented reality segment is of 

interest here: the Service Eye, which 

supports repairs and maintenance. 

Experts in the service headquarters in 

Germany are connected acoustically 

and visually, and can thus remotely 

control every work step together with 

the worker on the machine. Digital 

aids should in future also simplify 

orders of spare parts and consumables. 

Just like at Amazon, customers will be 

able to click through a virtual plant 

and select parts. 

3-D printing (or additive manufacturing) 

is also a segment with potential 

for Frech, of which Dr. Ioannidis and 

his team are well aware. Testing is 

already taking place with metal powders. 

Components of the casting plant, 

for example, can undergo close-contour 

cooling – with advantages for component 

durability, as well as for productivity 

of the process (reduced cycle 

time). 

Acknowledgement from 

the foundry industry 

The inventiveness and high status of 

research at Frech has also recently been 

honored by the German Foundry Association 

(BDG). At this year’s GIFA, the 


COMPANY 

team around Dr. Ioannidis was awarded 

the Innovation Prize of the German 

Foundry Industry – a prize for material, 

process or product development for 

companies or persons in the foundry 

sector. “We at Frech are proud that the 

German foundry industry, the leaders in 

Europe, selected us for the prize. The 

association represents our customers. 

This is a stimulus for our entire team,” 

Dr. Ioannidis assesses the award proudly. 

Frech passed on the 15,000 euro 

prizemoney to the BDG and the German 

Foundrymen’s Association (VDG) 

directly after being awarded it – to promote 

young up-and-coming talent. A 

small but richly symbolic step against 

the sector’s impending lack of skilled 

employees. 

The future offers much more 

And then – just at the end of our meeting 

in Schorndorf – Dr. Ioannidis 

majestically passes on some astonishing 

information that is really forward-looking: 

Frech is going to invest in the high 

double-digit millions to massively 

enlarge the Weiler site by 15,000 m² for 

a logistics center and two assembly halls 

for hot- and cold-chamber die-casting 

machines. This increases the production 

and commercial space to about 50,000 

m². He says that they also have new 

ideas, apart from the large-scale machines, 

for the Plüderhausen site. In addition, 

production capacity in Asia is to be 

increased with a new works for several 

million euros during the next two years. 

The message is clear: 70 years of history 

is not enough – the future offers much 

more for this successful German 

foundry supplier! 

www.frech.com 

From a small business to a global player 

Frech was founded in 1949 by engineer 

Oskar Frech, who initially produced 

tools with his wife in their home in 

Schorndorf. “It became time to expand 

when one day the spindle of a processing 

machine threatened to break 

through the ceiling,” relates Louis 

Braun, who has been working for Frech 

since the mid-1970s. The company’s history 

is reviewed on a wall about 50 

meters long. Frech only acquired its 

own company grounds in the Weiler 

suburb of Schorndorf – the current 

headquarters – two years after its founding. 

The first works expansion took 

place in 1958. At this time, about ten 

employees worked for the company. 

The first die-casting plant was put on 

the market in the early 1960s: a 

hot-chamber die-casting machine with a 

clamping force of ten tonnes, for materials 

such as tin, zinc and lead. In the 

days when Chancellor Ludwig Erhard, 

the cigar-smoking overseer of Germany’s 

economic miracle, ruled the republic 

the works in Weiler was expanded 

for the serial assembly of hot-chamber 

die-casting machines in 1963 – the starting 

signal for today’s success. 

Step-by-step the Schorndorf-based 

engineers appropriated other business 

segments: firstly, they launched a 

hot-chamber die-casting machine for 

magnesium in the late 1960s, then the 

first cold-chamber die-casting machine. 

They successfully entered the die-casting 

business themselves with the acquisition 

of Moneva in 1971. Frech thus got 

the opportunity to test its plant technology 

in practice. At about the same 

time, the first automation elements 

made their appearance in plant technology: 

“spraying equipment, removal 

devices and trimming presses came 

along,” Braun recalls. In addition, the 

newly founded Frech Leasing henceforth 

simplified financing of the machines. 

The number of employees rapidly 

rose to about 110 in the mid-1970s due 

to the construction of a new works in 

Schorndorf-Weiler with its own tool 

construction department. This is when 

the internationalization – driven by 

Wolfgang Frech after he took over from 

his father Oskar Frech in 1965 – also 

took off. A first subsidiary in France 

kicked off the setting-up of a global 

sales and service network that now 

includes large parts of the EU and Russia, 

as well as more distant markets such 

as Mexico, Southeast Asia, India, China, 

and the USA. 

Internationalization accelerated 

during the 1980s. The subsidiary in 

Shanghai had been founded by the end 

of the decade (and was later converted 

to an efficient production site in 2015). 

The Robamat subsidiary for producing 

tempering units was founded during the 

1990s, during which the joint venture 

Spesima GmbH in Bulgaria was also initiated 

for the automation of die-casting 

plants. Furnace constructor Meltec joined 

the Frech Group in 2000. The largest 

acquisition in the company’s history took 

place in 2007 with the take over of 

cold-chamber rival Müller Weingarten. 

The Group made a further important 

purchase – the Swiss vacuum technology 

company VDS – in 2013. Vacuum technology 

can be used to dispel air inclusions 

in castings, and thus optimize quality. 

44

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3-D-PRINTING 

Photos: Voxeljet 

Thanks to its 900 hp the Brabus G900 accelerates in less than four seconds to 100 km/h. 

With the turbo from the 

3-D printer to 900 hp 

Vehicle technology manufacturer Lütgemeier increases flexibility and productivity 

using the Voxeljet VX1000 3-D printing system in order to supply the high-performance 

car tuning company Brabus 

Frederik von Saldern, Voxeljet AG, Friedberg 

In order to produce sand casting 

molds for metal casting faster and 

more cost-effectively, the vehicle technology 

manufacturer Lütgemeier GmbH 

relies on the VX1000 printing system 

from voxeljet. The 3-D printing system 

does not only speed up the production 

of special components, which are used 

in racing cars of well-known German 

manufacturers. It also gives designers a 

whole new scope for production. The 

3-D printing systems from voxeljet 

enable time savings of up to 60 percent 

in the production of complex components. 

The Lütgemeier 

GmbH from Steinhagen 

near Bielefeld. 

The vehicle technician 

specializes in 

high-performance 

components for 

racing and vehicle 

refiners. 

46

The VX1000-PDB also 

offers space for large-format 

casting 

projects with a 

construction space of 

1000 x 600 x 500 mm. 

Modern racing cars or performance-enhanced 

luxury cars offer up to 900 

hp and accelerate from 0 to 100 km/h in 

less than four seconds. They are only 

capable of achieving that due to customized 

and finely engineered components 

underneath the bonnet - including 

specially adapted compressor 

housings, gearboxes, turbochargers, oil 

pumps and throttlebodies. These are 

produced by specialist manufacturers 

such as Lütgemeier GmbH from Steinhagen 

near Bielefeld in Germany. The 

company has been manufacturing 

vehicle and engine parts for renowned 

car manufacturers such as the high-performance 

tuning company Brabus from 

Bottrop for more than 30 years. “We 

can handle the entire manufacturing 

process internally. Starting from the 

design of the component, to casting 

and post-processing, all the way down 

to assembly and quality assurance, everything 

happens in-house, at Lütgemeier 

GmbH“, says CEO Jochen Hülsmann. 

The challenge: In the automotive 

industry, requirements and component 

geometries are becoming increasingly 

complex. The production of casting 

molds in which the molten metal takes 

on the shape of the component is thus 

becoming more costly and time-consuming, 

among other things, because an 

elaborate production of special tools is 

required. Nevertheless, in order to be 

able to guarantee customers flexibility 

and short delivery times, Lütgemeier 

CEO Hülsmann searched for an automation 

solution. He found it in voxeljet, a 

manufacturer of industrial 3-D printing 

systems with its head office in Friedberg 

near Augsburg, Germany. Hülsmann 

Lütgemeier employees 

take over the 

assembly of the 

printed sand molds. 

invested in the VX1000 PDB (Phenolic 

Direct Binding), a professional 3-D-printing 

system for industrial applications. 

Developed and manufactured in Germany, 

it measures 2800 x 2400 x 2300 

mm and weighs 3.5 tonnes. „Having 

had only good experiences with the 

printed molds from the voxeljet service 

centre, we decided to invest in our own 

3-D printing system“, says Hülsmann. 

“And the VX1000 prints very reliably”. 

Therefore, current system utilization at 

Lütgemeier is one hundred percent. In 

peak periods of extremely high 

demand, Lütgemeier continues to use 

the proven voxeljet service in Friedberg 

to satisfy the demand for 3-D-printed 

components. 

3-D printing system manufactures 

molds without the 

need for special tools 

The VX1000 enables the automated 

production of sand-casting molds. The 

user uploads a CAD file, the digital 

design plans of the sand mold onto the 

3-D printing system. The so-called recoater 

then applies a layer of silica sand 

just 300 microns thick onto the 1000 x 

600 x 500 millimetre large building platform. 

The print head then selectively 

doses a phenolic resin based binder on 

those areas where the casting mold is to 

be produced. A to the recoater attached 

mobile infrared lamp then heats 

the building platform in order to acce- 

Several CNC milling machines and lathes 

are available from Lütgemeier for post-processing 

of castings. 


3-D-PRINTING 

lerate the curing process of the binder. 

After that taskthe building platform is 

lowered by another layer of 300 µm 

and the process starts over and is repeated 

until the mold is fully constructed. 

“Binder jetting is the only proven and 

economical process for the automated 

production of sand-casting molds,” explains 

Hülsmann. After printing, an 

employee extracts the finished molds 

and removes excess silica sand with 

compressed air or a brush. Instead of 

giving the printed molds to foundries, 

which would again consume time, Lütgemeier 

GmbH casts not only lightweight 

alloys such as aluminium but 

also highly heat-resistant steels themselves 

in-house. In addition, the automotive 

specialist can also carry out the 

complete post-processing of the components 

directly. Several 5-axis milling 

machines as well as lathes and several 

measuring devices are available. Lütgemeier 

GmbH is thus able to produce 

Up to quality assurance 

Lütgemeier 

can map all essential 

steps of the value 

chain in-house. 

optimized components without lengthening 

the supply chain by making 

intermediate stops. 

The efficiency of this process optimization 

can be seen in a practical 

example. Brabus has specialized in the 

refinement of Mercedes Benz automobiles 

for over 40 years. Among others, 

Brabus created the Brabus G900 based 

on the Mercedes AMG G 65. The built-in 

V12 twin turbo engine delivers an incredible 

900 hp and accelerates the car to 

100 km/h in just 3.9 seconds. That is 

supercar performance in an off-road 

vehicle. This is possible through the 

optimisation of the engine’s performance. 

Tailor madeturbochargers with 

enlarged compressor housings from Lütgemeier 

contribute to this enormous 

increase in performance. 

60% time saving in the 

production of complex sandcasting 

molds 

Hülsmann is convinced of the investment 

in the 3-D printing system. After 

all, the time saved is significant. 

“Thanks to the printing system and the 

comprehensive “in-house” post-processing 

including quality assurance measures, 

we can achieve a time saving of up 

to 60 percent when manufacturing 

complex and qualitatively high-grade 

sand-casting molds”, says Hülsmann. 

Automation provides both increased 

flexibility and productivity and, ultimately, 

high levels of customer satisfaction, 

with components available more 

quickly and better than ever before 

„The finished cast parts are available 

faster and we can invest more time in 

the post-processing and optimization of 

individual components, depending on 

the customer‘s requirements. Or simply 

deliver faster,“ continues Hülsmann. 

An advantage that has gone down 

well with Brabus: “It is extremely time 

and cost intensive to increase the performance 

of an engine. The goal is to 

optimize the engine to maximum performance 

in a limited motor compartment. 

This is why 3-D printing is the 

perfect solution. Through the layer-bylayer 

construction, we can design geometries 

and components which could 

not be produced using conventional 

methods,” says Jörn Gander, Director of 

Technology and Development at Brabus. 

„The collaboration with Lütgemeier 

is characterized above all by the 

fast delivery of quality-assured and 

optimized components. We save on 

post-processing and can install the 

parts immediately. This is decisive for 

our development as well as assembly 

and gives us an advantage over our 

competitors“. 

An additional benefit: The costs of 

producing sand-casting molds are 

reduced. “For complex components up 

to a certain batch size, 3-D printing is 

always more favourable compared to 

conventional approaches due to the 

lack of tooling costs,” says Matthias 

Steinbusch, Sales Manager at voxeljet. 

“The smaller the batch size, the greater 

the cost benefit of using the voxeljet 

technology”. This also plays into the 

hands of Brabus. The G900 model is 

only available 10 times in this world. A 

batch size in which 3-D printing guarantees 

maximum efficiency in production. 

The compressor housing from Lütgemeier for the Brabus G900. 

300 dpi resolution: 3-D printing 

enables filigree geometries 

Phenolic Direct Binding also enables 

new design possibilities. „The freedom 

of design is far less restricted than with 

48

conventional methods. Designers do 

not have to pay attention to draft 

angles, dividing lines or undercuts and 

can realize even the most filigree interior 

geometries,“ says Steinbusch. The 

industrial Piezo print head of the 

VX1000 works with a resolution of up 

to 300 dpi. The unbonded silica sand is 

also one hundred percent recyclable in 

the PDB process and can be reused for 

the next print. A further cost benefit. 

But are the 3-D-printed molds really 

as rigid as to withstand the high casting 

pressure as the metal flows in? 

Steinbusch: „If you print very filigree 

coresin furanic resin, there is often a 

risk of breakage during casting.“ Phenolic 

resin as a binder makes it possible 

for cores from the 3-D printing system 

and classic mold making to achieve a 

higher level of stability. „The flexural 

strength achievable in the printing process 

is within the range of the strength 

of conventionally-manufactured cores 

with adjustable values between 300 and 

800 N/cm2. Therefore, the 3-D-printed 

molds are stable enough to reliably 

withstand the pressure of metal casting 

even with filigree hydraulic components”. 

Hülsmann is now planning an 

The Lütgemeier compressor housing is expertly mounted on the V12 engine at Brabus. 

expansion thanks to the reliability of 

the 3-D-printing system. In the future, 

he wants to offer the company’s services 

to machine manufacturers as well 

as vehicle manufacturers. So what can 

stand in the way? 

www.voxeljet.com 

Video: With the Turbo 

from the 3-D-Printer to 

900 hp 

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EUROGUSS-NEWS 

EUROGUSS 

Ongoing success story 

The Exhibition Centre Nuremberg will 

again become the meeting place for the 

die-casting industry for three days, from 

14 to 16 January 2020. In 2020 EURO- 

GUSS, the international trade fair for 

die casting will again have plenty to 

offer, with about 700 exhibitors in four 

halls for the first time, the Die Casting 

Conference with a top-quality lecture 

programme, and the special shows 

“Research for Knowledge” and “Surface 

Technology”. Another first is the 

Additive Manufacturing pavilion and 

the EUROGUSS Talent Award, a prize 

for emerging talents. EUROGUSS made 

a splash with strong growth in exhibitor 

numbers the last time it was held. And 

the success story will continue in 2020. 

“The preparations for EUROGUSS 2020 

could not have been better,” comments 

Christopher Boss, Director and International 

Product Manager of EUROGUSS. 

“All four halls are already fully booked, 

with growth of 17 percent, which shows 

we are absolutely on the right track 

with our trade fair strategy. All important 

die-casting foundries and their suppliers 

are once again represented 

among the exhibitors. That is a positive 

sign, especially considering the rather 

weak state of the economy, with regard 

to the automobile industry and its suppliers 

in particular, which includes the 

die casting foundries. For us, it is proof 

The trade fair also has a lot to offer in 2020: around 700 exhibitors in four halls for the first 

time, as well as the international die casting day with a high-caliber lecture program. 

that EUROGUSS is perceived as the meeting 

point for the die-casting industry.” 

More than half of the exhibitors at 

EUROGUSS are international. After 

Germany, the largest contingent of 

exhibitors comes from Italy, followed 

by Turkey, Spain, Austria and Switzerland. 

Die-casting foundries constitute 

the largest group of exhibitors, at 

about 39 percent. The balance of the 

exhibitors will be showcasing die-casting 

technologies including machines, 

peripheral devices, furnaces, molds, 

metals, alloys, and parting agents and 

operating materials. There are also 

products and services for aftertreatment 

of castings, quality assurance, 

control and drive technology, rapid 

prototyping, and software. 

www.euroguss.com 

Photo: MESSE NÜRNBERG 

FOSECO 

New technologies for die casting at EUROGUSS 

Due to its strong commitment to Research 

and Development and by working 

closely together with customers in 

developing new applications and solutions, 

Foseco will be showcasing new 

product and equipment technologies at 

EUROGUSS from January 14th to 16th 

2020. At the Foseco booth, visitors will 

discover new, innovative solutions for 

cost effective melting and holding of 

aluminium, optimized melt treatment, 

transfer and dosing. 

In recent years, several new features 

and technologies have been added to 

the Foseco FDU and MTS equipment 

range – the state of the art in technology 

for the automated treatment of an 

aluminium melt. SMARTT software 

offers various programs for rotary 

Foseco’s latest FEEDEX NF1 feeding technology 

for aluminium foundries 

degassing and the operator simply defines 

a melt quality after treatment. The 

software predicts the best treatment 

practice based on ambient conditions, 

melt temperature, rotor design and 

alloy composition. The treatment parameters 

are automatically transferred 

into the FDU MTS. In conjunction with 

innovative rotor designs Foseco guarantees 

a constant quality level and reliable 

results. SMARTT not only controls 

degassing but together with forming 

gas any defined hydrogen level can be 

reached. A customized report system 

records all parameters. 

The chemical grain refiner in granulated 

form can be added through the 

automated Metal Treatment Station. 

This grain refiner offers many advantages 

such as improved melt fluidity 

during casting, reduced inclusion level 

and better mechanical properties. The 

dross remaining after the treatment is 

low in metal which additionally saves 

Photo: Foseco 

50

INSURAL dosing furnace lining for aluminium 

foundries. 

costs. The dosing equipment uses a gravimetric 

load cell to ensure highest 

dosing precision for best metallurgical 

results as well as repeatability and traceability. 

COVERAL MTS fluxes are a 

range of new granulated treatment 

agents to cover the principal foundry 

operations of cleaning, drossing, modification 

and grain refinement. They 

have been specially formulated for use 

in conjunction with FDU and MTS which 

keep smoke and fume to a minimum. 

Shaft and rotor design are continuously 

improved to offer high efficiency in 

degassing at long service life. 

The longevity of a die coating is 

essential for the die casting process. 

Short lifetime leads to interruptions for 

touch-up, problems with mould filling 

and surface quality of the casting. 

The DYCOTE Safeguard products are 

nano-ceramic top coatings to be 

applied on top of the existing insulating 

DYCOTE base coating to increase the 

lifetime up to 300 % (depending on 

application). The longer lifetime leads 

to reduced interruptions for touch-up 

and therefore increased productivity. 

Foseco has recently launched the 

FEEDEX NF1 range of exothermic feeders 

designed for aluminium applications. 

The sleeve material is highly exothermic, 

provides a quick ignition and 

has a high strength and due to its excellent 

feeding performance, manual 

application of exothermic powders is 

avoided thereby reducing emissions. 

Furthermore the company offers a 

complete range of silicon carbide and 

clay graphite crucibles, retorts and 

other specialized shapes for use in fuel 

fired, induction and electric resistance 

furnaces. In the Non Ferrous metal 

transfer area crucibles from the ENER- 

TEK and DURATEK family highlight the 

energy and cost saving potential in melting, 

holding, and metal processing furnace 

applications. 

Monolithics also now play a significant 

role in modern aluminium foundries. 

Foseco’s ALUGARD low-cement castables 

and TRIAD no-cement castables 

contain a new aluminium “non-wetting” 

additive giving excellent resistance to 

corundum development across a wider 

temperature band, while the dry-vibratable 

lining KELLUNDITE is ideally suited 

to coreless induction melting furnaces. 

INSURAL multi-part and highly insulating 

dosing furnace linings for aluminium 

foundries combine energy savings 

with long-service life and resistance to 

oxide build-up. 

The use of energy efficient dosing 

furnaces is seen by many as the best 

available technology today. Foseco is 

now able to supply a new multi-part 

and highly insulating lining made of 

INSURAL which is delivered ready to 

install. Installation can be achieved in 

less than 3 days with no ongoing hydrogen 

issues and due to a totally dry installation 

process no sintering of the 

lining is necessary. Energy saving can be 

as high as 17%. www.foseco.com 

Hall 7A, Stand 523 

AGTOS 

Concept for blasting lightweight parts 

At the EUROGUSS exhibition, which 

takes place from 14 to 16 January 2020 

in Nuremberg, AGTOS will be addressing 

the distortion-free blasting of 

lightweight aluminum and magnesium 

components. 

The surface treatment of complex 

workpieces made of aluminum and magnesium 

is becoming increasingly demanding. 

Customers request a uniform surface 

finish on the entire component. In 

this context, the reproducibility for mass 

parts is important. Therefore, this topic 

complex is a focal point in the development 

of new blast machines at AGTOS. 

For example, special blast machines 

were developed for the machining of 

lightweight components and aluminum 

and magnesium die-cast parts. Actually, 

aluminum is used as abrasive as well. 

Considering the specifics of the material, 

this has implications for the design 

of the machines. The special features 

are presented at the AGTOS stand. 

The most important issue after 

investing in a blasting machine is the 

operating costs. With the help of the 

AGTOS Hanger type blast machine for Aluminium parts. 

right concept and the right turbines, 

these can be minimized accordingly. 

The service starts at AGTOS during the 

consultation and does not end with the 

commissioning. The visitors are cordially 

invited to convince themselves in personal 

conversations. In existing blasting 

machines, an increase in performance 

can be achieved. For example, turbines 

developed specifically for this application 

work more gently. Furthermore the 

abrasive consumption is lowered. 

www.agtos.de 

Hall 9, Stand 269 


NEWS 

CAEF 

Are perspectives bottoming out? 

The European Foundry Industry Sentiment 

fell slightly in October. The European 

foundries´ assessment of the current 

business situation was somewhat 

worse than in the previous month. By 

contrast, the outlook has improved 

slightly, but remains on a low level. This 

is in line with the slight improvement of 

the Business Climate Indicator of the 

Euro area. 

The trade tensions have eased due 

to no hard Brexit on 31st of October 

and due to signs for a possible partial 

agreement in the US-China conflict. 

Nevertheless, the export prospects 

remain fragile for the time being and 

potential punitive tariffs on European 

passenger car and component deliveries 

to the US are still being considered. 

Against this background and given 

declining orders, the question arises to 

which extent the expectations will stabilise 

at a low level in the medium 

term. 

The FISI – European Foundry Industry 

Sentiment Indicator – is the earliest 

available composite indicator providing 

information on the European foundry 

industry performance. It is published by 

CAEF the European Foundry Association 

FISI 

160 

150 

140 

130 

120 

110 

100 

90 

80 

70 

60 

Jan 08 

Jul 08 

Jan 09 

Jul 09 

Jan 10 

Jul 10 

Jan 11 

Jul 11 

Jan 12 

Jul 12 

Jan 13 

Jul 13 

Jan 14 

Jul 14 

Jan 15 

Jul 15 

Jan 16 

Jul 16 

Jan 17 

Jul 17 

Jan 18 

Jul 18 

Jan 19 

Jul 19 

Source: 

FISI: CAEF, Index 2015=100, country weight based on production 2017 

BCI: Eurostat, calculation CAEF 

FISI 

European Foundry Industry Sentiment Indicator (FISI) and Business Climate Indicator Euro 

Area (BCI) October 2019 

BCI 

5 

4 

3 

2 

1 

0 

-1 

-2 

-3 

-4 

BCI 

- 1 - © CAEF, www.caef.eu 

every month and is based on survey responses 

of the European foundry industry. 

The CAEF members are asked to 

give their assessment of the current 

business situation in the foundry sector 

and their expectations for the next six 

months. 

The BCI – Business Climate Indicator 

– is an indicator published by the European 

Commission. The BCI evaluates 

development conditions of the manufacturing 

sector in the euro area every 

month and uses five balances of opinion 

from industry survey: production 

trends, order books, export order 

books, stocks and production expectations. 

 

www.caef.eu 

Graphics: CAEF 

ICME 

British Foundry Medal goes to German 

foundry supplier 

The British Institute of Cast Metals 

Engineers (ICME) has awarded the British 

Foundry Medal to the German 

foundry supplier GTP Schäfer from Grevenbroich. 

The manufacturer of feeders 

gets the honoring for the best development 

and the article „ECO-Riser - the 

development of a high efficiency feeding 

system for iron castings using 

modular rise materials“ which was published 

in the September 2017 issue of 

the Foundry Trade Journal. Jörg and 

Thomas Schäfer, Nick Richardson, GTP 

Schaefer GmbH, and Thomas Baginski, 

GF Casting Solutions Leipzig GmbH 

were honored. GTP Schäfer sees the 

award as a confirmation of its corporate 

strategy. For the development of the 

ECO feeder system, the company has 

worked together with Georg Fischer in 

Leipzig. 

www.icme.org.uk 

Awarding of the British foundry medal at the Institute of Cast Metals Engineers ICME in 

West Bromwich, UK. 

Photo: GTP Schäfer 

52

HANDTMANN GROUP 

New production plant in Slovakia 

NEW 

Temperature control 

multiFlow modular 

Photo: Handtmann 

160 °C 

In addition to staff and managers from the customer and from the Handtmann Group of 

Companies, local representatives from the worlds of education and politics were guests at 

the groundbreaking ceremony on 23rd August, 2019 in Kechnec. 

The Light Metal Casting division of the 

Handtmann Group of Companies is 

increasing its production capacity with a 

new building in Kechnec, Slovakia, 

approximately 20 kilometres from the 

existing Handtmann plant in Košice. 

The groundbreaking ceremony for the 

new factory for aluminium high-pressure 

die-casting and mechanical machining 

was held on 23rd August, 2019. 

The building, designed to allow for 

expansion at a later date, is scheduled 

to begin a trial period as early as 2020 

and start production in 2021. Handtmann, 

which has its headquarters in 

Biberach, Germany, will invest a total of 

90 million euros in the new building. 

The first development stage will see 

the construction of a 210-metre long 

hall with a floorspace of 18,000 square 

metres divided into three sections. The 

casting hall will house six die casting 

machines, each with a closing force of 

3,200 tons. Machines for the mechanical 

machining of the cast parts will be 

installed in the second building section. 

The third section is reserved for logistics 

and support provisions, such as quality 

inspection, maintenance and media and 

energy supply. A great deal of experience 

gained by internal and external 

specialists has been tapped into for the 

design of the modular floor plan. In 

addition, Handtmann is also building an 

office and community building where 

the canteen, social rooms and changing 

rooms will be located. Approximately 

160 people will be employed in Kechnec 

in the first development stage. 

The new building was necessitated 

by a major contract from an international 

automotive supplier. In the future, 

Handtmann aims to cast and machine 

up to 800,000 clutch housings for a new 

generation of front-wheel drive vehicles 

in Kechnec. At the request of the customer, 

the new plant is located in the 

direct vicinity of their production facility. 

Handtmann had already bought 

the plot in 2006 in order to have an 

appropriate space in reserve. 

The Handtmann project team is working 

to a tight schedule, which is 

usually the case with this type of contract. 

As early as one year after the 

groundbreaking ceremony, the hall is 

scheduled to be completed to such an 

extent that plant installation can begin. 

The first casting at the new location is 

also planned for 2020 so that the customer 

can be supplied with appropriate 

trial parts at an early stage. Normal production 

is then set to start in 2021. 

www.handtmann.de 

Hall 7 - 423 

Networked Factory 4.0

NEWS 

GF CASTING SOLUTIONS 

Withdrawal from European automotive 

iron casting business completed 

As part of the strategic focusing of its 

portfolio, GF Casting Solutions, a division 

of GF, is divesting its iron foundry 

in Herzogenburg, Austria, to MRB Fer- 

Con GmbH. The transaction will have a 

negative one-off effect of 10 million 

Swiss franks (9,1 million euros) on the 

operating result in the second half of 

2019. 

As part of its Strategy 2020, GF Casting 

Solutions has taken several steps in 

recent months. The attractive aerospace 

and energy segments have been expanded 

systematically. In line with the 

trend toward lighter vehicles, the division 

has also strengthened its position 

in aluminum and magnesium light 

metal components. At the same time, 

the divestment of the German sites Singen 

and Mettmann at the end of 2018 

initiated the withdrawal from the automotive 

iron casting business in Europe. 

The foundry is being acquired by 

MRB FerCon GmbH, which was established 

by the two former GF executives 

Markus Rosenthal and Ralf Bachus. 

With around 250 employees, the plant 

generates sales of approx. 75 million 

Swiss francs (68 million euros). The 

light-metal foundry at the same location 

is not affected by the divestment. 

The transaction has taken place at 30 

September 2019. 

The iron foundry of GF Casting Solutions in Herzogenburg, Austria, is taken over by MRB 

FerCon GmbH. The company will be managed by the former GF executives Markus Rosenthal 

and Ralf Bachus. 

Andreas Müller, CEO of GF, says: 

“With this divestment, we are consistently 

implementing our Strategy 2020. 

We are pleased to divest the site with 

all 250 employees to an experienced 

and proven management team with 

comprehensive foundry and sector 

knowledge. Also with this transaction, 

the focus is on continuity for customers 

and employees.” 

With lean structures, the owners of 

MRB FerCon GmbH are convinced to 

respond swiftly and flexibly to the 

needs of the customers. Markus Rosenthal, 

owner of MRB FerCon, says: 

“Together with our employees, we look 

forward to further developing the Herzogenburg 

site.” 

www.gfcs.com 

Photo: GF Casting Solutions 

FRAUNHOFER IFAM 

Die-cast aluminum coils for efficient electric engines 

Whether pedelecs, e-scooters or drones 

– all these forms of mobility use an electric 

engine as drive. The engines are 

identical in construction and have a 

rotor, which is wrapped with a copper 

wire. In order to make the engines 

more efficient, the focus is on issues of 

efficiency, weight, material and production 

costs. Researchers at Fraunhofer 

IFAM in Bremen, Germany, have 

developed a casting technique that can 

be used to produce lightweight aluminum 

windings with a higher slot fill 

ratio. In one study it could be proven 

that the aluminum coils increase the 

continuous output of the electrical 

machines compared to the copper windings, 

reduce the operating temperature 

and at the same time save weight 

and raw material costs. 

After having already successfully 

realized aluminum coils in precision casting 

in recent years, it was an obvious 

goal of the department „Foundry Technology 

and Lightweight Construction“ 

at the Fraunhofer Institute for Manufacturing 

Technology and Applied 

Materials IFAM to produce the coils for 

series production also in die casting. 

Cast coils are characterized by a flat 

conductor arrangement, which leads to 

a higher slot fill ratio and thus to a better 

utilization of the available installation 

space. Although the cast aluminum 

coils have a higher electrical resistance 

relative to the wound copper coils, the 

larger cross-section results in less 

resistance with respect to the entire 

coil. Due to the better connection to 

the laminated core and more favorable 

utilization of the installation space a 

much better thermal and electromagnetic 

behavior results. For this reason, it 

is possible to replace wound copper 

coils with cast aluminum coils for improved 

performance and lower material 

costs. In order to prove this in a direct 

comparison, commercial pedelec engines 

with 250 watts were used for the 

study. The rebuilt engines with different 

laminated cores and coil combinations 

were then tested on a test bench. 

After the conversion of the pedelec 

engine, the slot fill ratio could be 

54

Die-cast aluminum 

coil with seven turns 

and a conductor 

height of approx. 

1.5 millimeters 

(Photo: Fraunhofer 

IFAM). 

increased from 32 to 60 percent. At the 

same time, there was a weight saving of 

10 percent. The torque increased by 30 

percent. Due to the better thermal 

behavior of the coils, the continuous 

power at operating temperature increased 

by almost 20 percent. The aluminum 

coil can deliver the resulting 

heat better to the laminated core and 

thus to the environment. This results in 

an improved continuous performance, 

since the coils only reach the permissible 

continuous operating temperature 

at higher currents. 

Even more advantageous were the 

measurement results for a laminated 

core optimized on the cast coils in another 

modified pedelec motor. At lower 

weight, the torque increased by almost 

80 percent and the continuous power 

by 25 percent compared to the original 

engine. Design changes can further 

increase the performance of aluminum 

coil motors. 

Thanks to many years of development 

work on cast coils at the Fraunhofer 

IFAM, it is now possible to cover a 

wide variety of application scenarios. 

For use in high-performance machines, 

copper coils of the highest quality can 

be produced by precision casting. For 

use in mass production, as required for 

example in the manufacture of steering 

motors or refrigeration and air conditioning 

systems, the die casting process is 

particularly suitable. In order to optimize 

the production in die casting and 

to further reduce the manufacturing 

costs, a next development step is the 

automated post-processing of the cast 

coils. Large quantities in low cycle times 

can then be manufactured in every die 

casting foundry. 

www.ifam.fraunhofer.de/en.html 

Photo: Fraunhofer IFAM 

FRAUNHOFER IGCV 

New center for foundry technology 

Photo: Sebastian Kissel 

Since 2016, the Fraunhofer Institute for 

Foundry, Composite and Processing 

Technology IGCV has been researching 

innovative foundry topics in Garching 

near Munich, Germany. In future, the 

scientists will find the best conditions 

to advance further developments in 

foundry technology: On October 11, 

2019, the foundation stone for a 

modern center for foundry technology 

was laid. „With the new building here 

in Garching, we are already expanding 

existing strategic and synergy effects 

with the neighboring Chair for Forming 

Technology and Foundry 

Engineering and other engineering 

faculties of the Technical University of 

Munich – thus strengthening our core 

competencies,“ says Institute Director 

Prof. Dr.-Ing. Wolfram Volk, „With this 

combination and in such a location, we 

are in an excellent position for interdisciplinary 

research.“ 

The focus is on the areas of molding 

materials, sand and mold casting processes 

and simulation. In the field of 

Laying of the foundation 

stone of the 

new center for 

foundry technology. 

On the right: Prof. 

Dr.-Ing. Wolfram 

Volk. 

molding materials, especially inorganic 

binders and novel combinations of 

molding base materials are of interest. 

In the field of sand and gravity mold 

casting innovative approaches to the 

integration of quality assurance measures 

as well as the embedding of casting 

systems in complete control solutions 

(Industry 4.0) are investigated. 

The Department of Simulation sets itself 

the task of closing existing gaps in 

the prediction of casting processes. In 

addition, exciting solutions for a 

long-distance cooperation are explored. 

These can be virtual production 

environments, but also augmented 

reality visualizations. 

In the future, various functional 

areas will be accommodated on the 

1,500 m² main floor space. The centerpiece 

is the foundry hall, which is supplemented 

by workshops, laboratory 

areas, meeting and seminar rooms, 

office areas for scientists, administration 

as well as communal and communication 

zones. The completion is 

planned for 2021, a total of 20 jobs 

will be created in the new technical 

center. 

www.igcv.fraunhofer.de/en.html 


NEWS 

WFO 

A global gathering in Slovenia 

Delegates from 27 countries attended 

the WFO Technical Forum and 59th IFC 

Portoroz on 18th to 20th September 

2019. Organized by the Slovenian 

Foundrymen Society, the event attracted 

over 400 attendees who took part 

in three days of business meetings, 

social events and technical conference 

presentations in the picturesque setting 

of Portoroz, on the Slovenian coastline. 

The World Foundry Organization (WFO) 

also held an Executive Board meeting 

and its annual general meeting of its 

member associations, the WFO General 

Assembly, during the event. Welcoming 

delegates, WFO President Mark Fenyes 

FICME of Omega Sinto Foundry Machinery 

Ltd said: “The WFO is delighted to 

be able to bring so many people 

together from around the world to discuss 

topical matters to enable the 

industry to continue to develop technology 

that places us at the forefront of 

innovative solutions for our customers. 

The WFO Technical Forum is an important 

part of the WFO portfolio of services 

that enable our member associations, 

along with companies and 

Dr. Carsten Kuhlgatz, Hüttenes-Albertus, WFO Secretary General Andrew Turner, 

WFO President Marc Fenyes and the President of the Slovenian Foundrymen Society 

Mirjam Jan Blasic at the WFO Technical Forum in Portoroz, Slovenia (from left) 

individuals in their countries, to share 

best practice and expand their competence 

in our industry. We thank the 

Slovenian Foundrymen Society, especially 

the President Mirjam Jan Blasic MSc, 

for their fabulous efforts to ensure the 

success of this year’s event.” 

www.thewfo.com 

Photo: Markus Winterhalter 

MARTINREA INT. 

Strategic relationship with Millison Die Casting 

Martinrea International Inc., Vaughan, 

Canada, a diversified and global automotive 

supplier engaged in the design, 

development and manufacturing of 

highly engineered, value-added Lightweight 

Structures and Propulsion Systems, 

announced a strategic relationship 

with Chongqing Millison Die 

Casting Co., Ltd. Based in Chongqing, 

China. Millison manufactures and distributes 

metal casting products for the 

automotive and telecommunications 

industries. The strategic relationship 

represents an expanded global manufacturing 

presence for Martinrea in 

Asia, and Millison in Europe and North 

America. Martinrea is present in 

Canada, the United States, Mexico, 

Brazil, Germany, Slovakia, Spain and 

China. 

“Millison brings a deep understanding 

of the Chinese market and provides 

an outlet for additional collaboration 

and growth with our customers,” 

said Pat D’Eramo, President and CEO, 

Martinrea International Inc. “We currently 

share a number of customers 

including, SAIC-GM, Nissan, Geely, Volvo 

and Ford. This relationship allows us to 

further expand our capabilities as a global 

supplier of aluminum castings.” 

Martinrea and Millison have signed 

a memorandum of understanding that 

allows the two entities to work 

together in the Chinese market. Initially, 

Martinrea and Millison plan to seek 

opportunities to manufacture aluminum 

body-in-white and powertrain 

components leveraging the robust 

technical resources and knowledge of 

high-pressure die casting (HPDC). 

“Having HPDC capabilities in China 

will allow us to improve our offering 

for our global customers and their global 

platforms,” said Robert Fairchild, 

Executive Vice President, Sales and 

Engineering, Martinrea International 

Inc. “It was important to select a China-based 

partner whose values align 

with our drive for new breakthrough 

opportunities and developing cutting 

edge technologies for die casting 

design and manufacturing.” 

Millison operates three manufacturing 

sites with more than 4,000,000 

square feet of land in Chongqing and 

Hubei Xiangyang employing more than 

2,000 employees. Millison owns advanced 

intelligent HPDC casting cells, 

high-precision CNC machining centers, 

automatic powder coating lines, with 

top quality-assurance systems and mold 

development. It has an annual output 

capacity of over 60,000 tons of large, 

complex and high-precision castings. 

“We look forward to collaborating 

with Martinrea International Inc. in the 

aluminum casting business,” said Arthur 

Yu, CEO of Millison Die Casting. 

“Both sides will use their resource 

advantages to strengthen alliances, 

better serve our customers, increase 

market share and achieve mutual 

benefit and win-win.” 

www.martinrea.com 

56

SUPPLIERS GUIDE 

CASTING 

PLANT AND TECHNOLOGY 

INTERNATIONAL 

© DVS Media GmbH 

Contact person: Vanessa Wollstein 

Aachener Straße 172 Phone: +49 211 1591-152 

40223 Düsseldorf Fax: +49 211 1591-150 

E-Mail: vanessa.wollstein@dvs-media.info 

1 Foundry Plants and Equipment 

17 Surface Treatment and Drying 

2 

Melting Plants and Equipment for Iron and 

Steel Castings and for Malleable Cast Iron 

18 

Plant, Transport, Stock, and Handling 

Engineering 

3 Melting Plants and Equipment for NFM 

4 Refractories Technology 

19 Pattern- and Diemaking 

20 Control Systems and Automation 

5 

6 

7 

8 

Non-metal Raw Materials and Auxiliaries for 

Melting Shop 

Metallic Charge Materials for Iron and Steel 

Castings and for Malleable Cast Iron 

Metallic Charge and Treatment Materials for 

Light and Heavy Metal Castings 

Plants and Machines for Moulding and 

Coremaking Processes 

21 Testing of Materials 

22 Analysis Technique and Laboratory 

23 Air Technique and Equipment 

24 Environmental Protection and Disposal 

9 Moulding Sands 

10 Sand Conditioning and Reclamation 

11 Moulding Auxiliaries 

12 Gating and Feeding 

13 Casting Machines and Equipment 

25 Accident Prevention and Ergonomics 

26 Other Products for Casting Industry 

27 Consulting and Service 

28 Castings 

29 By-Products 

14 

Discharging, Cleaning, Finishing of Raw 

Castings 

30 Data Processing Technology 

15 Surface Treatment 

16 Welding and Cutting 

31 Foundries 

32 Additive manufacturing / 3-D printing 




▼ Foundry Equipment and Facilities, in general 20 

HEINRICH WAGNER SINTO 

57334 Bad Laasphe, Germany 

( +49 2752 907-0 7 +49 2752 907-280 

Innernent: 

www.wagner-sinno.de 

▼ Second Hand Foundry Plants and Equipment 45 

TCT TESIC GmbH 

Foundry Marketing & Services 

58640 Iserlohn, Germany 

( +49 2371 77260 

Innernent: 

www.ncn-nesic.com 

02 Melting Plants and Equipment for Iron and 


02.06 Maintenance and Repairing 

▼ Repairing of Induction Furnaces 584 

TCT TESIC GmbH 

Foundry Marketing & Services 

58640 Iserlohn, Germany 

( +49 2371 77260 

Innernent: 

www.ncn-nesic.com 


03.02 Melting and Holding Furnaces, Electrically 

Heated 

▼ Aluminium Melting Furnaces 630 

▼ Remelting Furnaces 700 

LOI Thermoprocess GmbH 

45141 Essen/Germany 

( +49 201 1891-1 

E--ailt: 

loi@nenova.com 

Innernent: 

www.loi.nenova.com 


04.01 Plants, Equipment and Tools for Lining in Melting 

and Casting 

▼ Mixers and Chargers for Refractory Mixes 930 

UELZENER Maschinen GmbH 

Snahlsnr. 26-28, 65428 Rüsselsheim, Germany 

( +49 6142 177 68 0 

E--ailt: 

connacn@uelzener-ums.de 

Innernent: 

www.uelzener-ums.de 

▼ Gunning for Relining of Cupolas 950 



( +49 6142 177 68 0 

E--ailt: 


Innernent: 


▼ Wear Indicators for Refractory Lining 980 

Saveway GmbH & Co. KG 

Wümbacher Landsnraße 8, 98693 Ilmenau, Germany 

( +49 3677 8060-0 7 +49 3677 8060-99 

Innernent: 

www.saveway-germany.de 

▼ Wear Measuring and Monitoring for Refractory Lining 982 



( +49 3677 8060-0 7 +49 3677 8060-99 

Innernent: 


▼ State Diagnosis of Refractory Lines 985 

▼ Insulating Refractoy Bricks 1050 

Division Etex Industry 

Raningen/Germany 

E--ailt: 

www.proman-indusnry.com 

▼ Insulating Products 1130 



E--ailt: 


▼ Ceramic Fibre Mats, Papers, Plates, and Felts 1155 



E--ailt: 


▼ Micro Porous Insulating Materials 1220 



E--ailt: 


▼ Ladle Refractory Mixes 1240 



( +49 6142 177 68 0 

E--ailt: 


Innernent: 


04.04 Refractory Building 

▼ Maintenance of Refractory Linings 1462 



( +49 6142 177 68 0 

E--ailt: 


Innernent: 


05 Non-metal Raw Materials and Auxiliaries for 

Melting Shop 

05.04 Carburization Agents 

▼ Coke Breeze, Coke-Dust 1680 

ARISTON Formstaub-Werke GmbH & Co. KG 

Worringersnr. 255, 45289 Essen, Germany 

( +49 201 57761 7 +49 201 570648 

Innernent: 

www.arisnon-essen.de 

08 Plants and Machines for Moulding and 




( +49 201 1891-1 

E--ailt: 


Innernent: 


▼ Induction Furnaces (Mains, Medium, and High 

Frequency) 660 

INDUGA GmbH & Co. KG 

52152 Simmeranh, Germany 

E--ailt: 

info@induga.de 

Innernent: 

www.induga.com 



( +49 3677 8060-0 7 +49 3677 8060-99 

Innernent: 


04.02 Refractory Materials (Shaped and Non Shaped) 

▼ Refractories, in general 1040 

L. & F. PETERS GmbH 

E--ailt: 

www.peners-feuerfesn.de 

08.01 Moulding Plants 

▼ Moulding Machines, Fully and Partially Automatic 3070 



( +49 2752 907-0 7 +49 2752 907-280 

Innernent: 


Refratechnik Steel GmbH 

Refratechnik Casting GmbH 

Schiess-Snr. 58, 40549 Düsseldorf, Germany 

( +49 211 5858-0 

E--ailt: 

sneel@refra.com 

Innernent: 

www.refra.com 

58

08.02 Moulding and Coremaking Machines 

▼ Multi-Stage Vacuum Process 3223 

Pfeiffer Vacuum GmbH 

35614 Asslar, Germany 

( +49 6441 802-1190 7 +49 6441 802-1199 

E--ailt: 

andreas.wuerz@pfeiffer-vacuum.de 

Innernent: 

www.pfeiffer-vacuum.de 

▼ Automatic Moulding Machines 3100 



( +49 2752 907-0 7 +49 2752 907-280 

Innernent: 


▼ Moulding Machines, Boxless 3150 



( +49 2752 907-0 7 +49 2752 907-280 

Innernent: 


▼ Air-flow Squeeze Moulding Machines and Plants 3190 


09.01 Basic Moulding Sands 

▼ Chromite Sands 3630 

GTP Schäfer GmbH 

41515 Grevenbroich, Germany 

( +49 2181 23394-0 7 +49 2181 23394-55 

E--ailt: 

info@gnp-schaefer.de 

Innernent: 

www.gnp-schaefer.com 

▼ Ceramic Sands/Chamotte Sands 3645 



( +49 2181 23394-0 7 +49 2181 23394-55 

E--ailt: 


Innernent: 


▼ Silica Sands 3720 

STROBEL QUARZSAND GmbH 

Freihungsand, 92271 Freihung, Germany 

( +49 9646 9201-0 7 +49 9646 9201-1257 

E--ailt: 

info@snrobel-quarzsand.de 

Innernent: 

www.snrobel-quarzsand.de 

09.04 Mould and Core Coating 

▼ Blackings, in general 4270 

ARISTON Formstaub-Werke GmbH & Co. KG 

Worringersnr. 255, 45289 Essen, Germany 

( +49 201 57761 7 +49 201 570648 

Innernent: 

www.arisnon-essen.de 

▼ Mixers 4520 

Maschinenfabrik Gustav Eirich 

GmbH & Co KG 

Walldürner Snr. 50, 74736 Hardheim, Germany 

▼ Sand Mixers 4550 


GmbH & Co KG 


▼ Aerators 4560 


GmbH & Co KG 


▼ Scales and Weighing Control 4590 


GmbH & Co KG 


10.04 Sand Reconditioning 

▼ Sand Coolers 4720 


GmbH & Co KG 



▼ Covering Agents 5320 



( +49 2752 907-0 7 +49 2752 907-280 

Innernent: 


▼ Vacuum Moulding Machines and Processes 3280 



( +49 2752 907-0 7 +49 2752 907-280 

Innernent: 


08.03 Additives and Accessories 

▼ Core Handling 3450 



( +49 2752 907-0 7 +49 2752 907-280 

Innernent: 


09.06 Moulding Sands Testing 

▼ Moisture Testing Equipment for Moulding Sand 4410 


GmbH & Co KG 


▼ Moulding Sand Testing Equipment, in general 4420 


GmbH & Co KG 



▼ Sand Reclamation System 4448 



( +49 2752 907-0 7 +49 2752 907-280 

Innernent: 


10.01 Moulding Sand Conditioning 

▼ Aerators for Moulding Sand Ready-to-Use 4470 


GmbH & Co KG 


▼ Sand Preparation Plants and Machines 4480 

Refratechnik Steel GmbH 

Refratechnik Casting GmbH 

Schiess-Snr. 58, 40549 Düsseldorf, Germany 

( +49 211 5858-0 

E--ailt: 

sneel@refra.com 

Innernent: 

www.refra.com 

▼ Breaker Cores 5340 



( +49 2181 23394-0 7 +49 2181 23394-55 

E--ailt: 


Innernent: 


▼ Exothermic Products 5360 



( +49 2181 23394-0 7 +49 2181 23394-55 

E--ailt: 


Innernent: 


▼ Insulating Sleeves 5375 



( +49 2181 23394-0 7 +49 2181 23394-55 

E--ailt: 


Innernent: 


▼ Exothermic Mini-Feeders 5400 



( +49 2181 23394-0 7 +49 2181 23394-55 

E--ailt: 


Innernent: 


▼ Exothermic Feeder Sleeves 5420 


GmbH & Co KG 




( +49 2181 23394-0 7 +49 2181 23394-55 

E--ailt: 


Innernent: 




▼ Exothermic Feeding Compounds 5430 



( +49 2181 23394-0 7 +49 2181 23394-55 

E--ailt: 


Innernent: 



▼ Pouring Machines and Equipment 5436 

▼ Hydraulic Cylinders 5750 

HYDROPNEU GmbH 

Sudenensnr. , 73760 Osnfildern, Germany 

( +49 711 342999-0 7 +49 711 342999-1 

E--ailt: 

info@hydropneu.de 

Innernent: 

www.hydropneu.de 

▼ Piston Lubricants 5790 

14 Discharging, Cleaning, Finishing of Raw 

Castings 

14.05 Additional Cleaning Plants and Devices 

▼ Pneumatic Hammers 6940 

MD Drucklufttechnik GmbH & Co. KG 

Weissacher Snr. 1, 70499 Snunngarn, Germany 

( +49 711 88718-0 7 +49 711 88718-100 

Innernent: 

www.mannesmann-demag.com 



E--ailt: 


Innernent: 


13.01 Pouring Furnaces and their Equipment 

▼ Pouring Equipment 5450 



E--ailt: 


Innernent: 


▼ Pouring Equipment for Molding Plants, Railborn or 

Crane-operated 5470 

Chem-Trend (Deutschland) GmbH 

Robern-Koch-Snr. 27, 22851 Nordersnedn, Germany 

( +49 40 52955-0 7 +49 40 52955-2111 

E--ailt: 

service@chemnrend.de 

Innernent: 

www.chemnrend.com 

▼ Parting Agents for Dies 5850 



( +49 40 52955-0 7 +49 40 52955-2111 

E--ailt: 


Innernent: 


▼ Dry Lubricants (Beads) 5865 


▼ Heat Treatment and Drying 7398 

Gebr. Löcher Glüherei GmbH 

-ühlenseifen 2, 57271 Hilchenbach, Germany 

( +49 2733 8968-0 7 +49 2733 8968-10 

Innernent: 

www.loecher-glueherei.de 

17.01 Plants and Furnaces 

▼ Tempering Furnaces 7400 



( +49 2752 907-0 7 +49 2752 907-280 

Innernent: 




( +49 40 52955-0 7 +49 40 52955-2111 

E--ailt: 


Innernent: 


▼ Multi-Stage Vacuum Process 5876 



( +49 201 1891-1 

E--ailt: 


Innernent: 


▼ Ageing Furnaces 7401 



E--ailt: 


Innernent: 


13.02 Die Casting and Accessories 

▼ Diecasting Lubricants 5670 

Pfeiffer Vacuum GmbH 

35614 Asslar, Germany 

( +49 6441 802-1190 7 +49 6441 802-1199 

E--ailt: 

andreas.wuerz@pfeiffer-vacuum.de 

Innernent: 

www.pfeiffer-vacuum.de 

13.03 Gravity Die Casting 

▼ Gravity Diecasting Machines 5940 



( +49 201 1891-1 

E--ailt: 


Innernent: 


▼ Annealing and Hardening Furnaces 7430 



( +49 40 52955-0 7 +49 40 52955-2111 

E--ailt: 


Innernent: 


▼ Diecasting Parting Agents 5680 



( +49 2752 907-0 7 +49 2752 907-280 

Innernent: 


▼ Low Pressure Diecasting Machines 5980 



( +49 201 1891-1 

E--ailt: 


Innernent: 


▼ Solution Annealing Furnaces 7455 



( +49 40 52955-0 7 +49 40 52955-2111 

E--ailt: 


Innernent: 




( +49 2752 907-0 7 +49 2752 907-280 

Innernent: 




( +49 201 1891-1 

E--ailt: 


Innernent: 


60

▼ Annealing Furnaces 7490 


▼ Laser Measurement Techniques 9310 



( +49 201 1891-1 

E--ailt: 


Innernent: 


▼ Quenching and Tempering Furnaces 7510 

19.04 Rapid Prototyping 

▼ Pattern and Prototype Making 9025 

Georg Herrmann Metallgießerei GmbH 

-uldenhünnen 22, 09599 Freiberg, Germany 

( +49 3731 3969 0 7 +49 3731 3969 3 

E--ailt: 

mail@ghm-aluguss.de 

Innernent: 

www.ghm-aluguss.de 

POLYTEC GmbH 

76337 Waldbronn, Germany 

( +49 7243 604-0 7 +49 7243 69944 

E--ailt: 

Lm@polynec.de 

Innernent: 

www.polynec.de 

▼ Positioning Control 9345 



( +49 201 1891-1 

E--ailt: 


Innernent: 


▼ Heat Treating Furnaces 7520 


20.01 Control and Adjustment Systems 

▼ Automation and Control for Sand Preparation 9030 

POLYTEC GmbH 

76337 Waldbronn, Germany 

( +49 7243 604-0 7 +49 7243 69944 

E--ailt: 

Lm@polynec.de 

Innernent: 

www.polynec.de 

▼ Temperature Measurement 9380 


GmbH & Co KG 




( +49 201 1891-1 

E--ailt: 


Innernent: 


▼ Hearth Bogie Type Furnaces 7525 

▼ Automation 9040 

MINKON GmbH 

Heinrich-Hernz-Snr. 30-32, 40699 Erkranh, Germany 

( +49 211 209908-0 7 +49 211 209908-90 

E--ailt: 

info@minkon.de 

Innernent: 

www.minkon.de 

▼ Thermal Analysis Equipment 9400 



( +49 201 1891-1 

E--ailt: 


Innernent: 


18 Plant, Transport, Stock, and Handling 

Engineering 

18.01 Continuous Conveyors and Accessories 

▼ Flexible Tubes with Ceramic Wear Protection 7676 



( +49 2752 907-0 7 +49 2752 907-280 

Innernent: 


▼ Software for Production Planning and Control 9042 



( +49 2752 907-0 7 +49 2752 907-280 

Innernent: 


▼ Control Systems and Automation, in general 9090 

MINKON GmbH 


( +49 211 209908-0 7 +49 211 209908-90 

E--ailt: 


Innernent: 

www.minkon.de 

▼ Thermo Couples 9410 

MINKON GmbH 


( +49 211 209908-0 7 +49 211 209908-90 

E--ailt: 


Innernent: 

www.minkon.de 

STEIN INJECTION TECHNOLOGY GmbH 

Hagener Snr. 20-24, 58285 Gevelsberg, Germany 

( +49 2332 75742-0 7 +49 2332 75742-40 

E--ailt: 

snein@sin-gmbh.nen 

Innernent: 

www.sin-gmbh.nen 

▼ Vibratory Motors 7980 

FRIEDRICH Schwingtechnik GmbH 

Am Höfgen 24, 42781 Haan, Germany 

( +49 2129 3790-0 7 +49 2129 3790-37 

E--ailt: 

info@friedrich-schwingnechnik.de 

Innernent: 

www.friedrich-schwingnechnik.de 



( +49 2752 907-0 7 +49 2752 907-280 

Innernent: 


20.02 Measuring and Control Instruments 

▼ Immersion Thermo Couples 9230 

20.03 Data Acquisition and Processing 

▼ Data Logging and Communication 9440 



( +49 2752 907-0 7 +49 2752 907-280 

Innernent: 


MINKON GmbH 


( +49 211 209908-0 7 +49 211 209908-90 

E--ailt: 


Innernent: 

www.minkon.de 



▼ Machine Data Logging 9480 





( +49 2752 907-0 7 +49 2752 907-280 

Innernent: 


▼ Numerical Solidification Analysis and 

Process Simulation 9500 

MAGMA Giessereitechnologie GmbH 

Kackernsnr. 11, 52072 Aachen, Germany 

( +49 241 88901-0 7 +49 241 88901-60 

E--ailt: 

info@magmasofn.de 

Innernent: 

www.magmasofn.com 

▼ Numerical Solidification Simulation and Process Optimization 

9502 



( +49 241 88901-0 7 +49 241 88901-60 

E--ailt: 


Innernent: 


▼ Computer Programmes and Software for Foundries 9520 



( +49 2752 907-0 7 +49 2752 907-280 

Innernent: 


▼ Simulation Software 9522 



( +49 241 88901-0 7 +49 241 88901-60 

E--ailt: 


Innernent: 


▼ Software for Foundries 9523 



( +49 2752 907-0 7 +49 2752 907-280 

Innernent: 


▼ Fault Indicating Systems, Registration 

and Documentation 9540 

21.01 Testing of Materials and Workpieces 

▼ Dye Penetrants 9600 

KARL DEUTSCH 

Prüf- und Messgerätebau GmbH + Co. KG 

Onno-Hausmann-Ring 101, 42115 Wuppernal, Germany 

( +49 202 71 92-0 7 +49 202 71 49 32 

E--ailt: 

info@karldeunsch.de 

Innernent: 

www.karldeunsch.de 

▼ Instruments for Non-destructive Testing 9610 

KARL DEUTSCH 



( +49 202 71 92-0 7 +49 202 71 49 32 

E--ailt: 


Innernent: 


▼ Magnetic Crack Detection Equipment 9680 

KARL DEUTSCH 



( +49 202 71 92-0 7 +49 202 71 49 32 

E--ailt: 


Innernent: 


▼ Ultrasonic Testing Equipment 9750 

KARL DEUTSCH 



( +49 202 71 92-0 7 +49 202 71 49 32 

E--ailt: 


Innernent: 


▼ UV-Lamps 9758 

KARL DEUTSCH 



( +49 202 71 92-0 7 +49 202 71 49 32 

E--ailt: 


Innernent: 


▼ Devices for Testing of Materials, non-destructive, in 

general 9836 

KARL DEUTSCH 



( +49 202 71 92-0 7 +49 202 71 49 32 

E--ailt: 


Innernent: 


22 Analysis Technique and Laboratory Equipment 

▼ Sampling Systems 9970 

26.02 Industrial Commodities 

▼ Joints, Asbestos-free 11120 

MINKON GmbH 


( +49 211 209908-0 7 +49 211 209908-90 

E--ailt: 


Innernent: 

www.minkon.de 

▼ Sealing and Insulating Products up to 1260 øC 11125 

MINKON GmbH 


( +49 211 209908-0 7 +49 211 209908-90 

E--ailt: 


Innernent: 

www.minkon.de 


▼ Machining 11292 

Behringer GmbH 

Maschinenfabrik und Eisengiesserei 

Posnfacht: 

1153, 74910 Kirchardn, Germany 

( +49 7266 207-0 7 +49 7266 207-500 

Innernent: 

www.behringer.nen 

▼ Simulation Services 11310 



( +49 241 88901-0 7 +49 241 88901-60 

E--ailt: 


Innernent: 


▼ Heat Treatment 11345 

Gebr. Löcher Glüherei GmbH 

-ühlenseifen 2, 57271 Hilchenbach, Germany 

( +49 2733 8968-0 7 +49 2733 8968-10 

Innernent: 

www.loecher-glueherei.de 

28 Castings 



( +49 2752 907-0 7 +49 2752 907-280 

Innernent: 


MINKON GmbH 


( +49 211 209908-0 7 +49 211 209908-90 

E--ailt: 


Innernent: 

www.minkon.de 

▼ Aluminium Pressure Diecasting 11390 

Schött Druckguß GmbH 

Aluminium Die Casting 

Posnfacht: 

27 66, 58687 -enden, Germany 

( +49 2373 1608-0 7 +49 2373 1608-110 

E--ailt: 

vernrieb@schoenn-druckguss.de 

Innernent: 

www.schoenn-druckguss.de 

▼ Rolled Wire 11489 



Posnfacht: 


( +49 7266 207-0 7 +49 7266 207-500 

Innernent: 


62

▼ Spheroidal Iron 11540 



Posnfacht: 


( +49 7266 207-0 7 +49 7266 207-500 

Innernent: 


▼ Steel Castings 11550 

KS Gleitlager GmbH, Werk Papenburg 

Friesensnr. 2, 26871 Papenburg, Germany 

( +49 4961 986-150 7 +49 4961 986-166 

E--ailt: 

sales-cc@de.rheinmenall.com 

Innernent: 

www.rheinmenall-aunomonive.com 

31 Foundries 

31.01 Iron, Steel, and Malleable-Iron Foundries 

▼ Iron Foudries 11855 



Posnfacht: 


( +49 7266 207-0 7 +49 7266 207-500 

Innernent: 


31.02 NFM Foundries 

▼ Light Metal Casting Plants 11862 

Georg Herrmann Metallgießerei GmbH 

-uldenhünnen 22, 09599 Freiberg, Germany 

( +49 3731 3969 0#fax#+49 3731 3969 3 

E--ailt: 

mail@ghm-aluguss.de 

Innernent: 

www.ghm-aluguss.de 

Innernent: 


▼ Mold Filling and Solidification Simulation 11700 



( +49 241 88901-0 7 +49 241 88901-60 

E--ailt: 


Innernent: 


Index to Companies 

Company Product Company Product 

ARISTON Formsnaub-Werke GmbH & Co. KG 1680, 4270 

BEHRINGER GmbH 11292, 11489, 11540, 11855 

-aschinenfabrik&Eisengießerei 

Chem Trend (Deunschland) GmbH 5670, 5680, 5790, 5850, 5865 

-aschinenfabrik 4410, 4420, 4470, 4480, 4520, 

Gusnav Eirich GmbH & Co KG 4550, 4560, 4590, 4720, 9030 

Enex Building Performance GmbH 1050, 1130, 1155, 1220 

Friedrich Schwingnechnik GmbH 7980 

GTP Schäfer 3630, 3645, 5340, 5360, 5375, 

Giessnechnische Produkne GmbH 5400, 5420, 5430 

Heinrich Wagner Sinno 20, 3070, 3100, 3150, 3190, 

-aschinenfabrik GmbH 3280, 3450, 4448, 5470, 5940, 

5980, 9040, 9042, 9090, 9440, 

9480, 9520, 9523, 9540 

HYDROPNEU GmbH 5750 

INDUGA GmbH & Co. KG 660, 5436, 5450, 5470 

KARL DEUTSCH Prüf- und 9600, 9610, 9680, 9750, 9758, 

-essgeränebau GmbH + Co KG 9836 

KS Gleinlager GmbH Werk Papenburg 11550 

Gebr. Löcher Glüherei GmbH 7398, 11345 

LOI Thermprocess GmbH 630, 700, 7400, 7401, 7430, 

7455, 7490, 7510, 7520, 7525 

-AG-A Gießereinechnologie GmbH 9500, 9502, 9522, 11310, 11700 

-D Drucklufnnechnik GmbH & Co. KG 6940 

Georg Herrmann -enallgießerei GmbH 9025, 11862 

-INKON GmbH 9230, 9380, 9400, 9410, 9970, 

11120, 11125 

L. & F. PETERS GmbH 1040 

Pfeiffer Vacuum GmbH 3223, 5876 

Polynec GmbH 9310, 9345 

Refranechnik Sneel GmbH 1040, 5320 

Saveway GmbH & Co. KG 980, 982, 985 

Schönn-Druckguß GmbH 11390 

Snein Injecnion Technology GmbH 7676 

Snrobel Quarzsand GmbH 3720 

TCT TESIC GmbH 45, 584 

Uelzener -aschinen GmbH 930, 950, 1240, 1462 


List of Products 


10 Foundry Plants, Planning and 

Construction 

20 Foundry Equipment and Facilities, 

in general 

30 Foundry Plants, fully and 

partially automatic 

40 Maintenance and Repairing of 

Foundry Plants 

44 Swing-Technique Machines for 

Handling, Dosing, and Classing 

45 Second Hand Foundry Plants and 

Equipment 

47 Spray Deposition Plants 

01.01. Components 

47 Spray Deposition Plants 

50 Charging Systems, in general 

52 Cored Wire Treatment Stations 

53 Plug Connections, Heat Resisting 

02 Melting Plants and Equipment for Iron and 


02.01. Cupolas 

55 Cupolas 

60 Hot-Blast Cupolas 

70 Cold-Blast Cupolas 

80 Circulating Gas Cupolas 

90 Gas Fired Cupolas 

100 Cupolas, cokeless 

110 Cupolas with Oxygen-Enrichment 

120 Cupolas with Secondary Blast 

Operation 

02.02. Cupola Accessories and 

Auxiliaries 

130 Lighter 

140 Cupola Charging Equipment 

150 Tuyères 

160 Burners for Cupolas 

180 Blowing-In Equipment for Carbo Fer 

190 Blowing-In Equipment for Filter 

Dusts into Cupolas 

210 Blowing-In Equipment for Carbon 

211 Blowing-In Equipment for Metallurgical 

Processes 

220 Dedusting, Cupolas 

225 Gas Cleaning 

230 Charging Plants, fully and partially 

automatic 

240 Blowers, Cupolas 

270 Recuperators 

280 Oxygen Injection for Cupolas 

290 Shaking Ladles, Plants 

295 Dust Briquetting 

300 Monitoring Plants, Cupola 

310 Forehearths, Cupola 

320 Blast Heater 

02.03. Melting and Holding 

Furnaces, Electrically Heated 

330 Electric melting Furnaces, in general 

340 Induction Channel Furnaces 

350 Crucible Induction Furnaces, medium 

Frequency 

360 Crucible Induction Furnaces, 

Mains Frequency 

370 Short-Coil Induction Furnaces 

390 Filters, in general 

399 Tower Melter 

400 Holding Furnaces 

02.04. Accessories and Auxiliaries 

for Electric Furnaces 

410 Charging Units 

420 Blowing-In Equipment for Carbo Fer 

430 Blowing-In Equipment for Filter Dusts 

440 Blowing-In Equipment for Carbon 

445 Inert Gas Systems for EAF and EIF 

450 Inert Gas Systems for EAF and EIF 

460 Electro-magnetic Conveyor Chutes 

470 Dust Separation Plant 

480 Charging Equipment 

500 Graphite Electrodes 

510 Lime Dosing Device 

520 Condensors 

540 Cooling Equipment 

550 Scrap preheating Plants 

560 Secondary Metallurgical Plants 

565 Control Installations 

570 Equipment for induction stirring 

02.05. Rotary Furnaces 

580 Rotary Furnaces 

02.06. Maintenance and Repairing 

584 Repairing of Induction Furnaces 

586 Maintenance of Complete 

Induction Furnace Plants 


03.01. Melting Furnaces, Fuel Fired 

590 Hearth-Type (Melting) Furnaces 

599 Tower Furnaces 

600 Bale-Out Furnaces 

610 Crucible Furnaces 

620 Drum-Type Melting Furnaces 

03.02. Melting and Holding 

Furnaces, Electrically Heated 

630 Aluminium Melting Furnaces 

640 Dosing Furnace 

655 Heating Elements for Resistance 

Furnaces 

660 Induction Furnaces (Mains, 

Medium, and High Frequency) 

665 Magnesium Melting Plants and 

Dosing Devices 

670 Melting Furnacs, in general 

680 Bale-Out Furnaces 

690 Crucible Furnaces 

700 Remelting Furnaces 

710 Holding Furnaces 

720 Electric Resistance Furnaces 

902 Vacuum Melting and Casting 

Furnaces 

03.03. Accessories and Auxiliaries 

730 Exhausting Plants 

740 Molten Metal Refining by Argon 

742 Gassing Systems for Aluminium 

Melting 

750 Gassing Systems for Magnesium 

Melting 

760 Charging Plants 

770 Blowing-in Equipment for Alloying 

and Inoculating Agents 

774 Blowing-in Equipment for 

Inoculating Agents 

778 Degassing Equipment 

780 Dedusting Equipment 

785 Crucibles, Ready-To-Use 

790 Charging Equipment 

800 Graphite Melting Pots 

825 Emergency Iron Collecting 

Reservoirs 

847 Cleaning Devices for Cleaning 

Dross in Induction Furnaces 

848 Cleaning Device and Gripper for 

Deslagging - Induction Furnaces 

850 Crucibles 

860 Inert Gas Systems 

870 Silicon Carbide Pots 

875 Special Vibrating Grippers for 

the Removal of Loose Dross and 

Caking 

880 Gas Flushing Installations 

890 Crucibles, Pots 

895 Power Supply, Plasma Generators 

900 Vacuum Degassing Equipment 


04.01. Plants, Equipment and Tools for 

Lining in Melting and Casting 

910 Spraying Tools for Furnace Lining 

920 Breakage Equipment for Cupolas, 

Crucibles, Pots, Torpedo Ladles 

and Ladles 

923 Lost Formers 

930 Mixers and Chargers for 

Refractory Mixes 

940 Charging Units for Furnaces 

950 Gunning for Relining of Cupolas 

954 Ramming Mix Formers 

956 Ramming Templates 

980 Wear Indicators for Refractory Lining 

982 Wear Measuring and Monitoring 

for Refractory Lining 

985 State Diagnosis of Refractory Lines 

64

04.02. Refractory Materials 

(Shaped and Non Shaped) 

1000 Boron-Nitride Isolation 

1005 Sand Gaskets, Isolation 

Materials (up to 1260 °C) 

1009 Running and Feeding 

Systems (Gating Systems) 

1010 Running and Feeding Systems 

(Runner Bricks, Centre Bricks, 

Sprue Cups) 

1020 Fibrous Mould Parts 

1021 Fibrous Mould Parts up to 1750 °C 

1030 Refractory Castables 

1040 Refractories, in general 

1050 Insulating Refractoy Bricks 

1060 Refractoy Cements 

1070 Refractories for Aluminium Melting 

Furnaces 

1080 Refractory Materials for Anode 

Kilns 

1090 Refractory Materials for Melting 

Furnaces, in general 

1100 Refractory Materials for Holding 

Furnaces 

1103 Ceramic Fibre Mould Parts and 

Modules 

1104 Mold Sections and Modules made 

of HTW (High Temperature Wool) 

1109 Precasts 

1110 Pouring Lip Bricks 

1113 Fibreglass Mats 

1114 Slip Foils for Glowing Materials 

1117 High Temperature Mats, Papers, 

Plates, and Felts 

1120 Induction Furnace Compounds 

1123 Insulating and Sealing Panels up 

to 1200 °C 

1125 Insulating Fabrics up to 1260 °C 

1128 Insulating Felts and Mats up to 

1260 °C 

1130 Insulating Products 

1140 Insulating Products (such as 

Fibres, Micanites) 

1150 Insulating Bricks 

1155 Ceramic Fibre Mats, Papers, 

Plates, and Felts 

1160 Ceramic Fibre Modules 

1169 Ceramic Fibre Substitutes 

1170 Ceramic Fibre Products 

1180 Loamy Sands 

1190 Carbon Bricks 

1200 Cupola and Siphon Mixes 

1210 Cupola Bricks 

1220 Micro Porous Insulating Materials 

1222 Nano Porous Insulating Materials 

1225 Furnace Door Sealings, Cords, and 

Packings 

1230 Furnace Linings 

1240 Ladle Refractory Mixes 

1250 Ladle Bricks 

1260 Plates, free from Ceramic Fibres 

1261 Plates made of Ground Alkali 

Silicate Wool 

1270 Acid and Silica Mixes 

1280 Fire-Clay Mixes and Cements 

1290 Fire-Clay Bricks 

1310 Porous Plugs 

1312 Stirring Cones for Steel, Grey Cast 

Iron and Aluminium 

1320 Moulding Mixtures for Steel Casting 

1330 Ramming, Relining, Casting, 

Gunning, and Vibration Bulks 

1333 Ramming, Casting, Gunning, and 

Repairing Compounds 

1340 Plugs and Nozzles 

1345 Textile Fabrics up to 1260 °C 

988 Substitutes of Aluminium Silicate 

Wool 

990 Coating and Filling Materials, 

Protective Coatings 

04.03. Refractory Raw Materials 

1350 Glass Powder 

1360 Loamy Sands 

1370 Magnesite, Chrom-Magnesite, 

Forsterite 

1390 Chamotte, Ground Chamotte 

1400 Clays, Clay Powders 

04.04. Refractory Building 

1410 Bricking-Up of Furnaces 

1420 Refractory Building/Installation 

1430 Fire and Heat Protection 

1435 Furnace Door Joints 

1440 Furnace Reconstruction 

1450 Repairing of Furnaces and Refractories 

1460 Heat Insulation 

1462 Maintenance of Refractory Linings 

05 Non-metal Raw Materials and Auxiliaries for 

Melting Shop 

05.01. Coke 

1480 Lignite Coke 

1490 Foundry Coke 

1510 Petroleum Coke 

05.02. Additives 

1520 Desulphurization Compounds 

1530 Felspar 

1540 Fluorspar 

1550 Casting Carbide 

1560 Glass Granulate 

1570 Lime, Limestones 

1575 Briquets for Cupolas 

1580 Slag Forming Addition 

05.03. Gases 

1590 Argon 

1600 Oxygen 

1610 Inert Gases 

1620 Nitrogen 

1622 Hydrogen 

05.04. Carburization Agents 

1630 Carburization Agents, in general 

1640 Lignite Coke 

1650 Electrode Butts 

1660 Electrode Graphite 

1665 Desulfurizer 

1670 Graphite 

1680 Coke Breeze, Coke-Dust 

1700 Petroleum Coke 

1710 Silicon Carbide 

3261 Automatic Powder Feeding 

05.05. Melting Fluxes for NF-Metals 

1720 Aluminium Covering Fluxes 

1730 Desoxidants, in general 

1740 Degassing Fluxes 

1750 Desulphurisers 

1760 Charcoal 

1770 Refiners 

1780 Fluxing Agents 

1785 Melt Treatment Agents 

1790 Fluxing Agents 

06 Metallic Charge Materials for Iron and Steel 

Castings and for Malleable Cast Iron 

06.01. Scrap Materials 

1810 Cast Scrap 

1811 Cast Turnings 

1813 Cuttings/Stampings 

1817 Steel Scrap 

06.02. Pig Iron 

1820 Hematite Pig Iron 

1830 Foundry Pig Iron 

1838 DK Pig Iron 

1840 DK-Perlit Special Pig Iron 

1880 DK Pig Iron for Malleable Cast Iron 

1898 DK Pig Iron, low-carbon, Quality 

DKC 

1900 DK-Perlit Special Pig Iron, Low 

Carbon, DKC Quality 

1936 DK Phosphorus Alloy Pig Iron 

1940 DK-Perlit Special Pig Iron, Type 

Siegerlaender 

1950 Spiegel Eisen 

1970 Blast Furnace Ferro Silicon 

06.03. Specials (Pig Iron) 

1990 Foundry Pig Iron 

2000 Hematite Pig Iron 

2010 Sorel Metal 

2020 Special Pig Iron for s. g. Cast Iron 

Production 

2030 Special Pig Iron for s.g. Cast Iron 

2040 Steelmaking Pig Iron 

06.04. Ferro Alloys 

2050 Ferro-Boron 

2060 Ferro-Chromium 

2070 Ferroalloys, in general 

2080 Ferro-Manganese 

2090 Ferro-Molybdenum 

2100 Ferro-Nickel 

2110 Ferro-Niobium 

2120 Ferro-Phosphorus 

2130 Ferro-Selenium 

2140 Ferro-Silicon 

2150 Ferro-Silicon-Magnesium 

2160 Ferro-Titanium 

2170 Ferro-Vanadium 

2180 Ferro-Tungsten 

2190 Silicon-Manganese 

06.05. Other Alloy Metals and Master 

Alloys 

2200 Aluminium Granulates 

2210 Aluminium, Aluminium Alloys 

2220 Aluminium Powder 

2230 Aluminium Master Alloys 

2250 Calcium Carbide 

2260 Calcium-Silicon 

2265 Cerium Mischmetal 



2280 Chromium Metals 

2290 Cobalt 

2300 Chromium Metal, Aluminothermic 

2310 Deoxidation Alloys 

2318 High-grade Steel 

2320 Iron Powder 

2350 Copper 

2360 Cupola Briquets 

2370 Alloying Metals, in general 

2380 Alloying Additives 

2390 Magnesium, Magnesium Alloys 

2410 Manganese Metal 

2420 Manganese Metal, Electrolytic 

2430 Molybdenum 

2440 Molybdenum Alloys 

2450 Molybdenum Oxide 

2460 Nickel, Nickel Alloys 

2470 Nickel-Magnesium 

2490 Furnace Additives 

2500 Ladle Additives 

2510 High-Purity Iron, Low-Carbon 

2520 Sulphuric Iron 

2530 Silicon Carbide 

2540 Silicon Metal 

2545 Silicon Metal Granules 

2550 Special Alloys 

2570 Titanium Sponge 

2575 Master Alloys for Precious Metals 

2580 Bismuth 

2590 Tungsten 

2600 Tin 

2610 Alloying Metals, Master Alloys 

06.06. Nodularizing Additives and 

Auxiliaries 

2620 Magnesium Treatment Alloys for 

s. g. Cast Iron 

2630 Mischmetal 

06.07. Inoculants and Auxiliary 

Appliances 

2640 Cored-Wire Injectors 

2645 Injection Appliances for Cored Wire 

2650 Cored Wires for Secondary and 

Ladle Metallurgy 

2653 Cored Wires for Magnesium Treatment 

2656 Cored Wires for Inoculation of Cast 

Iron Melts 

2658 Stream Inoculants 

2660 Automatic IDA-Type Inoculation 

Dosing Devices 

2670 Injection Appliances 

2680 Inoculants and Inoculation Alloys, 

in general 

2690 Inoculants for Cast Iron 

2692 MSI Pouring Stream Inoculation 

Devices 

2694 Ladle Inoculants 

07 Metallic Charge and Treatment Materials for 

Light and Heavy Metal Castings 

07.01. Scrap 

2730 Metal Residues 

07.02. Ingot Metal 

2740 Standard Aluminium Alloys 

2750 Brass Ingots 

2770 High-Grade Zinc Alloys 

2790 Copper 

2800 Copper Alloys 

2810 Magnesium, Magnesium Alloys 

2830 Tin 

07.03. Alloying Addition for Treatment 

2838 Aluminium-Beryllium Master Alloys 

2840 Aluminium-Copper 

2852 Aluminium Master Alloys 

2870 Arsenic Copper 

2875 Beryllium-Copper 

2890 Calcium 

2891 Calcium Carbide, Desulphurisers 

2893 Chromium-Copper 

2900 Ferro-Copper 

2910 Grain Refiner 

2920 Granulated Copper 

2924 Copper Magnesium 

2925 Copper Salts 

2927 Copper Master Alloys 

2930 Alloy Metals, in general 

2935 Alloy Biscuits 

2936 Lithium 

2938 Manganese Chloride (anhydrate) 

2940 Manganese Copper 

2950 Metal Powder 

2960 Niobium 

2970 Phosphor-Copper 

2980 Phosphor-Tin 

2990 Silicon-Copper 

3000 Silicon Metal 

3010 Strontium, Strontium Alloys 

3020 Tantalum 

3025 Titanium, powdery 

3030 Refining Agents for Aluminium 

3033 Zirconium-Copper 

08 Plants and Machines for Moulding and 


08.01. Moulding Plants 

3050 Moulding Plants, in general 

3058 Moulding Machines, Boxless 

3060 Moulding Machines, Fully Automatic 

3070 Moulding Machines, Fully and 

Partially Automatic 

08.02. Moulding and Coremaking 

Machines 

3080 Lifting Moulding Machine 

3090 Pneumatic Moulding Machines 

3100 Automatic Moulding Machines 

3110 High-Pressure Squeeze Moulding 

Machines 

3130 Impact Moulding Machines 

3140 Moulding Plants and Machines for 

Cold-Setting Processes 

3150 Moulding Machines, Boxless 

3160 Core Blowers 

3170 Coremaking Machines 

3180 Core Shooters 

3190 Air-flow Squeeze Moulding Machines 

and Plants 

3200 Shell Moulding Machines 

3210 Shell Moulding Machines 

3220 Shell Moulding Machines and 

Hollow Core Blowers 

3225 Multi-Stage Vacuum Process 

3230 Multi-Stage Vacuum Processes for 

Pressure Die Casting Processes 

3235 Rapid Prototyping 

3240 Jolt Squeeze Moulding Machines 

3250 Suction Squeeze Moulding Machines 

and Plants 

3260 Pinlift Moulding Machines 

3270 Rollover Moulding Machines 

3280 Vacuum Moulding Machines and 

Processes 

3290 Multi-Piston Squeeze Moulding 

Machines 

3300 Turnover Moulding Machines 

08.03. Additives and Accessories 

3310 Exhaust Air Cleaning Plants for 

Moulding Machines 

3320 Gassing Units for Moulds and 

Cores 

3325 Seal Bonnets for Immersion Nozzles 

3330 Metering Dosing Devices for 

Binders and Additives 

3340 Electrical Equipment for Moulding 

Machines and Accessories 

3350 Electrical and Electronic Controlling 

Devices for Moulding 

Machines 

3355 Mould Dryer 

3360 Vents 

3370 Screen-Vents 

3380 Spare Parts for Moulding Machines 

3390 Flow Coating Plants 

3400 Pattern Plates 

3420 Manipulators 

3430 Core Setting Equipment 

3440 Core Removal Handling 

3450 Core Handling 

3460 Coremaking Manipulators 

3462 Core Transport Racks 

3470 Shell Mould Sealing Equipment 

and Presses 

3480 Mixers for Blackings and Coatings 

3500 Plastic Blowing and Gassing Plates 

3510 Coating Equipment 

3512 Coating Dryers 

3520 Equipment for Alcohol-based 

Coatings 

3525 Coating Stores and 

Preparation Equipment 

3530 Coating Mixers, Coating Preparation 

Equipment 

3540 Screen Vents, front Armoured 

3560 Swing Conveyors 

3570 Screening Machines 

3580 Plug Connections, Heat-Resisting 

08.04. Mould Boxes and Accessories 

3590 Moulding Boxes 

3610 Moulding Box Round-hole and 

Long-hole Guides 


09.01. Basic Moulding Sands 

3630 Chromite Sands 


3645 Ceramic Sands/Chamotte Sands 

3650 Core Sands 

66

3660 Molochite 

3670 Mullite Chamotte 

3690 Olivine Sands 

3700 Fused Silica 

3705 Lost Foam Backing Sands 

3710 Silica Flour 

3720 Silica Sands 

3730 Zircon Powder 

3740 Zircon Sands 

09.02. Binders 

3750 Alkyd Resins 

3755 Inorganic Binders 

3760 Asphalt Binders 

3770 Bentonite 

3790 Binders for Investment Casting 

3800 Cold-Box Binders 

3803 Resins for the Shell Moulding 

Process 

3820 Ethyl Silicate 

3830 Moulding Sand Binders, in general 

3833 Binders, Inorganic 

3840 Resins 

3860 Oil Binders 

3870 Core Sand Binders, in general 

3875 Silica Sol 

3880 Synthetic Resin Binders, in general 

3890 Synthetic Resin Binders for 

Refractories 

3900 Synthetic Resin Binder for Gas 

Curing Processes 

3910 Synthetic Resin Binder for Hot 

Curing Processes 

3920 Synthetic Resin Binder for Cold 

Setting Processes 

3930 Facing Sand Binders 

3940 Binders for the Methyl-Formate 

Process 

3950 Phenolic Resins 

3960 Phenolic Resins (alkaline) 

3970 Polyurethane Binders and Resins 

3980 Swelling Binders 

3990 Swelling Clays 

4000 Quick-Setting Binders 

4010 Silicate Binders 

4020 Silica Sol 

4030 Binders for the SO2 Process 

4040 Cereal Binders 

4050 Warm-Box Binders 

4060 Water-Glass Binders (CO2-Process) 

09.03. Moulding Sand Additives 

4066 Addition Agents 

4070 Iron Oxide 

4080 Red Iron Oxide 

4090 Lustrous Carbon Former 

4100 Pelleted Pitch 

4110 Coal Dust 

4120 Coal Dust Substitute (Liquid or 

Solid Carbon Carrier) 

4130 Coal Dust (Synthetic) 

09.04. Mould and Core Coating 

4140 Inflammable Coating 

4150 Alcohol-Based Coatings 

4160 Alcohol-based Granulated Coatings 

4170 Boron-Nitride Coatings 

4180 Coatings, Ready-to-Use 

4190 Mould Varnish 

4200 Mould Coating 

4210 Black Washes 

4220 Graphite Blackings 

4224 Lost-Foam Coatings 

4225 Ceramic Coatings 

4230 Core Coatings 

4240 Core Blackings 

4260 Paste Coatings 

4266 Coatings (with metallurgical effects) 

4270 Blackings, in general 

4280 Steel Mould Coatings 

4290 Talc 

4298 Coatings for Full Mould Casting 

4300 Water-based Coatings 

4310 Granulated Water-based Coatings 

4320 Zircon Coatings 

4321 Zircon-free Coatings 

09.05. Moulding Sands 

Ready-to-Use 

4340 Sands for Shell Moulding, Readyto-use 

4350 Sands Ready-to-Use, Oil-Bonded 

(Water-free) 

4360 Precoated Quartz Sands, Zircon 

Sands, Chromite Sands, Ceramic 

Sands 

4370 Moulding Sands for Precision 

Casting 

4380 Steel Moulding Sands 

4390 Synthetic Moulding and Core Sand 

09.06. Moulding Sands Testing 

4400 Strength Testing Equipment for 

Moulding Sand 

4410 Moisture Testing Equipment for 

Moulding Sand 

4420 Moulding Sand Testing Equipment, 

in general 

4426 Core Gas Meters for Al + Fe 

4440 Sand Testing 


4446 Sand Preparation and 

Reclamation 

4448 Sand Reclamation System 

10.01. Moulding Sand Conditioning 

4450 Nozzles for Moistening 

4459 Continuous Mixers 

4460 Continuous Mixers for Cold-Setting 

Sands 

4470 Aerators for Moulding Sand 

Ready-to-Use 

4480 Sand Preparation Plants and 

Machines 

4490 Sand Mullers 

4500 Measuring Instruments for Compactibility, 

Shear Strength, and 

Deformability 

4510 Measuring Instruments for 

Mouldability Testing (Moisture, 

Density, Temperature) 

4520 Mixers 

4550 Sand Mixers 

4560 Aerators 

4567 Vibration Sand Lump Crusher 

4568 Vibratory Screens 

4570 Sand Precoating Plants 

4590 Scales and Weighing Control 

10.03. Conditioning of Cold, Warm, 

and Hot Coated Sands 

4650 Preparation Plants for Resin 

Coated Sand 

10.04. Sand Reconditioning 

4660 Used Sand Preparation Plants 

4662 Batch Coolers for Used Sand 

4664 Flow Coolers for Used Sand 

4670 Magnetic Separators 

4690 Core Sand Lump Preparation 

Plants 

4700 Reclamation Plants for Core Sands 

4710 Ball Mills 

4720 Sand Coolers 

4730 Sand Reclamation Plants 

4740 Sand Screens 

4760 Separation of Chromite/Silica Sand 

10.05. Reclamation of Used Sand 

4780 Reclamation Plants, in general 

4785 Reclamation Plants, 

Chemical-Combined 


Mechanical 


Mechanical/Pneumatic 


Mechanical-Thermal 

4820 Reclamation Plants, Mechanical/ 

Thermal/Mechanical 

4830 Reclamation Plants, wet 

4840 Reclamation Plants, Thermal 


Thermal-Mechanical 

11 Moulding Auxiliaries 

4880 Mould Dryers 

4890 Foundry Nails, Moulding Pins 

4910 Moulders‘ Tools 

4920 Mould Hardener 

4950 Guide Pins and Bushes 

4965 High Temperature Textile Fabrics 

up to 1260 °C 

4970 Ceramic Pouring Filters 

4980 Ceramic Auxiliaries for Investment 

Foundries 

4990 Ceramic Cores for Investment 

Casting - Gunned, Pressed, Drawn 

4998 Cope Seals 

5000 Core Benches 

5007 Core Putty Fillers 

5010 Core Wires 

5020 Cores (Cold-Box) 

5030 Cores (Shell) 

5040 Core Boxes 

5050 Core Box Dowels 

5070 Core Adhesives 

5080 Core Loosening Powder 

5090 Core Nails 

5100 Core Powders 

5110 Chaplets 

5130 Tubes for Core and Mould Venting 



5140 Core Glueing 

5150 Core Glueing Machines 

5155 Cleaners 

5160 Adhesive Pastes 

5170 Carbon Dioxide 

(CO2 Process) 

5180 Carbon Dioxide Dosing 

Devices 

5210 Coal Dust and Small Coal 

5220 Chill Nails 

5230 Chill Coils 

5240 Antipiping Compounds 

5260 Shell Mould Sealers 

5270 Mould Dryers, Micro-Wave 

5280 Screening Machines 

5290 Glass Fabric Filters 

5300 Strainer Cores 

5310 Release Agents 

11.01. Moulding Bay Equipment 




5320 Covering Agents 

5330 Heating-up Agents 

5340 Breaker Cores 


5360 Exothermic Products 


5370 Insulating Products and Fibres 

5375 Insulating Sleeves 

5380 Ceramic Filters 

5390 Ceramic Breaker Cores 

5400 Exothermic Mini-Feeders 

5405 Non-Ceramic Foam Filters 

5410 Ceramic Dross Filters 

5416 Riser (exothermic) 

5418 Riser (insulating) 

5420 Exothermic Feeder Sleeves 

5430 Exothermic Feeding Compounds 


5436 Pouring Machines and 

Equipment 

5437 Casting Machine, 

without Heating 

13.01. Pouring Furnaces and their 

Equipment 

5440 Aluminium Dosing Furnaces 

5450 Pouring Equipment 

5460 Pouring Ladles 

5461 Pouring Ladles, Insulating 

5468 Pig and Ingot Casting 

Machines 

5470 Pouring Equipment for Moulding 

Plants, Railborn or Crane-operated 

5480 Pouring Ladles 

5485 Pouring Ladles, Electrically Heated 

5490 Drum-Type Ladles 

5500 Ingot Casting Machines 

5510 Low Pressure Casting 

Machine 

13.02. Die Casting and 

Accessories 

5530 Trimming Presses for 

Diecastings 

5540 Trimming Tools for Diecastings 

(Standard Elements) 

5545 Exhausting and Filtering Plants for 

Diecastings 

5550 Ejectors for Diecasting Dies 

5560 Ejectors for Diecasting Dies (Manganese 

Phosphate Coated) 

5570 Feeding, Extraction, Spraying, and 

Automatic Trimming for Diecasting 

Machines 

5580 Trimming Tools 

5600 Dosing Devices for 

Diecasting Machines 

5610 Dosing Furnaces for 


5620 Diecasting Dies 

5630 Heating and Cooling Devices for 

Diecasting Dies 

5640 Diecasting Machines 

5641 Diecasting Machines and Plants 

5644 Diecasting Machines for Rotors 

5650 Diecasting Machine Monitoring 

and Documentation Systems 

5660 Diecasting Coatings 

5670 Diecasting Lubricants 

5675 Lost Diecasting Cores 

5680 Diecasting Parting Agents 

5689 Venting Blocks for HPDC Dies 

5690 Extraction Robots for 


5695 Frames and Holders for 


5700 Spraying Equipment for Diecasting 

Machines 

5710 Goosenecks and Shot Sleeves 

5720 Hand Spraying Devices 

5730 Heating Cartridges 

5740 High-duty Heating Cartridges 

5750 Hydraulic Cylinders 

5760 Core Pins 

5770 Cold Chamber Diecasting Machines 

5780 Pistons for Diecasting Machines 

5790 Piston Lubricants 

5800 Piston Spraying Devices 

5810 Mixing Pumps for Parting Agents 

5815 Electric Nozzle Heatings 

5817 Oil Filters 

5820 Melting and Molten Metal Feeding 

in Zinc Die Casting Plants 

5830 Steel Molds for Diecasting Machines 

5838 Heating and Cooling of Dies 

5840 Temperature Control Equipment for 


5850 Parting Agents for Dies 

5860 Parting Agent Spraying Devices for 


5865 Dry Lubricants (Beads) 

5870 Vacural-Type Plants 



5890 Vacuum Die Casting Plants 

5900 Hot Working Steel for 


5910 Hot Working Steel for Diecasting 

Tools 

5912 Hot Chamber Diecasting Machines 

13.03. Gravity Die Casting 

5914 Dosing Devices for Gravity Diecasting 

Stations 

5920 Permanent Molds 

5930 Automatic Permanent Moulding 

Machines 

5940 Gravity Diecasting Machines 

5941 Gravity and High Pressure Diecasting 

Automation 

5945 Cement and Fillers for Permanent 

Moulds up to 1600 °C 

5950 Cleaning Devices for Permanent 

Molds 

5960 Coatings for Permanent Molds 

5970 Colloidal Graphite 

5975 Chills 

5980 Low Pressure Diecasting Machines 

13.04. Centrifugal Casting 

5990 Centrifugal Casting Machines 

13.05. Continuous Casting 

6000 Anode Rotary Casting Machines 

6001 Length and Speed Measuring, 

non-contact, for Continuous 

Casting Plants 

6002 Thickness and Width Measurement 

for Continuous Casting 

Plants, non-contact 

6006 Casting and Shear Plants for 

Copper Anodes 

6007 Casting and Rolling Plants for 

Copper Wire 

6008 Casting and Rolling Plants for 

Copper Narrow Strips 

6010 Continuous Casting Plant, horizontal, 

for Tube Blanks with integrated 

Planetary Cross Rolling Mill for the 

Production of Tubes 

6020 Continuous Casting Moulds 

6030 Continuous Casting 

Machines and Plants 

6032 Continuous Casting, Accessories 

6033 Continuous Casting Machines and 

Plants (non-ferrous) 

13.06. Investment and Precision 

Casting 

6040 Burning Kilns for Investment 

Moulds 

6045 Investment Casting Waxes 

6050 Embedding Machines for Investment 

Casting Moulding Materials 

6060 Investment Casting Plants 

6062 Centrifugal Investment 

Casting Machines 

13.07. Full Mould Process Plants 

6070 Lost-Foam Pouring Plants 

13.08. Auxiliaries, Accessories, and 

Consumables 

6080 Pouring Manipulators 

6090 Slag Machines 

6093 Copper Templates 

6100 Nozzles, Cooling 

68

6110 Electrical and Electronic Control 

for Casting Machines 

6120 Extraction Devices 

6130 Pouring Consumables, in general 

6140 Rotary Casting Machines 

6150 Pouring Ladle Heaters 

6160 Ladle Bails 

6170 Stream Inoculation Devices 

6175 Graphite Chills 

6176 Marking and Identification 

6177 Bone Ash (TriCalcium Phosphate) 

6190 Long-term Pouring Ladle Coatings 

6200 Long-term Lubricants 


6220 Ladle Covering Compounds 

6240 Robots 

6245 Protective Jacket for Robots, Heat 

and Dust Resistant 

6250 Dosing Devices for Slag Formers 

Addition 

6270 Silicon Carbide Chills 

6280 Silicon Carbide Cooling Compounds 

6290 Crucible Coatings 

6300 Heat Transfer Fluids 

14 Discharging, Cleaning, Finishing of Raw 

Castings 

6305 Casting Cooling Plants 

14.01. Discharging 

6330 Knock-out Drums 

6340 Vibratory Shake-out Tables 

6345 Knock-out Vibratory Conveyors 

6346 Shake-out Grids 

6347 Shake-out Separation Runners 

6350 Decoring Equipment 

6352 Discharging of Metal Chips 

6360 Hooking 


6373 Manipulators for Knock-out Floors 

6380 Robots 

6390 Vibratory Grids, Hangers, and 

Chutes 

6400 Vibratory Tables 

14.02. Blast Cleaning Plants and 

Accessories 

6410 Turntable Blasting Fans 

6420 Pneumatic Blasting Plants 

6430 Automatic Continuous Shot-blasting 

plants 

6440 Descaling Plants 

6445 Spare Parts for Blasting Plants 

6450 Hose Blasting Plants, Fans 

6460 Hose Blasting Chambers 

6470 Monorail Fettling Booths 

6475 Efficiency Tuning for Blasting 

Plants 

6480 Manipulator Shotblast Plants 

6485 Tumbling Belt Blasting Plants, 

Compressed Air Driven 

6490 Wet and Dry Shotblast Plants 

6500 Fettling Machines 

6530 Airless Blast Cleaning Machines 

6540 Blasting Plants Efficiency Tuning 

6550 Shot Transport, Pneumatic 

6560 Shot-Blasting Plants 

6569 Shot Blasting Machines 

6570 Shot Blasting Machines, with/ 

without Compressed Air Operating 

6572 Dry Ice Blasting 

6574 Dry Ice Production 

14.03. Blasts 

6580 Aluminium Shots 

6590 Wire-Shot 

6600 High-Grade Steel Shots 

6610 Granulated Chilled Iron, Chilled 

Iron Shots 

6630 Cast Steel Shots 

6640 Stainless Steel Shot 

6650 Shot-Blast Glass 

6660 Shot-Blast Glass Beads 

6670 Blasts 

6671 Stainless Steel Abrasives 

14.04. Grinding Machines and Accessories 

6675 Stainless Steel Grit 

6680 Belt Grinders 

6685 chamfering machines 

6690 Flexible Shafts 

6695 Diamond Cutting Wheels for 

Castings 

6700 Compressed Air Grinders 

6710 Fibre discs 

6714 Centrifugal Grinders 

6720 Vibratory Cleaning Machines and 

Plants 

6730 Rough Grinding Machines 

6735 Abrasive Wheels, visual, with 

Flakes/Lamellas 

6740 Numerical Controlled Grinders 

6750 Swing Grinders 

6760 Polishing Machines 

6770 Polishing Tools 

6773 Precision Cutting Wheels, 0,8 mm 

6780 Tumbling Drums 

6790 Pipe Grinders 

6800 Floor Type Grinders 

6810 Grinding Textiles 

6820 Emery Paper 

6830 Grinding Wheel Dresser 

6850 Grinding Wheels and Rough 

Grinding Wheels 

6855 Grinding Pins 

6860 Grinding Fleece 

6870 Grinding Tools 

6874 Drag Grinding Plants 

6880 Rough Grinding Machines 

6885 Cutting Wheels 

6890 Abrasive Cut-off Machines 

6900 Vibratory Cleaning Machines 

6910 Angle Grinders 

14.05. Additional Cleaning Plants 

and Devices 

6920 Gate Break-off Wedges 

6925 Plants for Casting Finishing 

6930 Automation 

6940 Pneumatic Hammers 

6950 Deflashing Machines 

6954 Deburring Machines, 

robot-supported 

6955 Robot Deburring Systems 

6960 Fettling Cabins 

6970 Fettling Manipulators 

6980 Fettling Benches 

6990 Core Deflashing Machines 

7000 Chipping Hammers 

7010 Dedusting of Fettling Shops 

7020 Fettling Hammers 

7030 Fettling Shops, Cabins, Cubicles 

7035 Refining Plants 

7040 Robot Fettling Cubicles 

7041 Robot Deflashing Units for Casting 

7050 Feeder Break-off Machines 

7052 Stamping Deflashing 

Equipment (tools, presses) 

7055 Break-off Wedges 

7056 Cutting and Sawing Plants 

7058 Band Saw Blades 

7059 Cut-off Saws 

7060 Cut-off Saws for Risers and Gates 

14.06. Jig Appliances 

7066 Magnetic Clamping Devices for 

Casting Dies 

7068 Core-Slides and Clamping 

Elements for Casting Dies 

7070 Clamping Devices 

14.07. Tribology 

7073 Lubricants for High Temperatures 

7074 Chain Lubricating Appliances 

7075 Cooling Lubricants 

7077 Central Lubricating Systems 


7083 Anodizing of Aluminium 

7100 Pickling of High Quality Steel 

7105 CNC Machining 

7110 Paint Spraying Plants 

7115 Yellow/Green Chromating 

7130 Priming Paints 

7140 Casting Sealing 

7150 Casting Impregnation 

7166 Hard Anodic Coating of Aluminium 

7180 High Wear-Resistant Surface 

Coating 

7190 Impregnation 

7198 Impregnation Plants 

7200 Impregnating Devices and Accessories 

for Porous Castings 

7210 Anticorrosion Agents 

7220 Corrosion and Wearing Protection 

7230 Shot Peening 

7232 Wet Varnishing 


7235 Surface Coatings 

7240 Polishing Pastes 

7245 Powder Coatings 

7250 Repair Metals 

7260 Slide Grinding, free of Residues 

7290 Quick Repair Spaddle 

7292 Special Coatings 

7295 Special Adhesives up to 1200 °C 

7296 Shot-Blasting 

7297 Power Supply, Plasma Generators 

7300 Galvanizing Equipment 

7302 Zinc Phosphating 

7310 Scaling Protection 

7312 Subcontracting 



16 Welding and Cutting 

16.01. Welding Machines and 

Devices 

7330 Welding Consumables, Electrodes 

16.02. Cutting Machines and Torches 

7350 Gougers 

7352 Special Machines for Machining 

7360 Coal/Graphite Electrodes 

7365 Water Jet Cutting 

7370 Oxygen Core Lances 

16.03. Accessories 

7394 Protective Blankets, Mats, and 

Curtains, made of Fabric, up to 

1250 °C 

7397 Protective Welding Paste, up to 

1400 °C 


7398 Heat Treatment and Drying 

17.01. Plants and Furnaces 

7400 Tempering Furnaces 

7401 Ageing Furnaces 

7402 Combustion Chambers 

7404 Baking Ovens for Ceramic Industries 

7420 Mould Drying Stoves 

7430 Annealing and Hardening Furnaces 

7440 Induction Hardening and Heating 

Equipment 

7450 Core Drying Stoves 

7452 Microwave Drying Stoves and 

Chambers 

7455 Solution Annealing Furnaces 

7460 Ladle Dryers 

7470 Sand Dryers 

7480 Inert Gas Plants 

7490 Annealing Furnaces 

7500 Drying Stoves and Chambers 

7510 Quenching and Tempering Furnaces 

7520 Heat Treating Furnaces 

7525 Hearth Bogie Type Furnaces 

17.02. Components, Accessories, 

Operating Materials 

7550 Multi-purpose Gas Burners 

7560 Heating Equipment, in general 

7564 Special Torches 

7580 Firing Plants 

7590 Gas Torches 

7600 Gas Heatings 

7610 Capacitors 

7616 Furnace Optimization 

7620 Oil Burners 

7630 Recuperative Burners 

7640 Oxygen Burners 

7650 Heat Recovery Plants 

18 Plant, Transport, Stock, and Handling 

Engineering 

7654 Lifting Trucks 

7656 Transport, Stock, and 

Handling Technology 

18.01. Continuous Conveyors and 

Accessories 

7660 Belt Conveyors 

7670 Bucket Elevators 

7676 Flexible Tubes with Ceramic Wear 

Protection 

7680 Conveyors, in general 

7690 Conveyors, Fully Automatic 

7710 Conveyor Belts 

7720 Conveyor Belt Ploughss 

7730 Conveyor Belt Idlers 

7740 Conveyor Chutes 

7750 Conveying Tubes 

7760 Belt Guides 

7780 Overhead Rails 

7790 Hot Material Conveyors 

7810 Chain Conveyors 

7820 Chain Adjusters 

7850 Conveyors, Pneumatic 

7860 Roller Beds, Roller Conveyor 

Tables, Roller Tables 

7870 Sand Conveyors 

7890 Bulk Material Conveyors 

7900 Swing Conveyor Chutes 

7910 Elevators 

7920 Chip Dryers 

7950 Idlers and Guide Rollers 

7960 Transport Equipment, in general 

7970 Conveyor Screws 

7980 Vibratory Motors 

7981 Vibration Conveyors 

18.02. Cranes, Hoists, and 

Accessories 

8000 Grippers 

8010 Lifting Tables and Platforms 

8020 Jacks and Tilters 

8030 Operating Platforms, Hydraulic 

8032 Hydraulic and Electric Lifting 

Trucks 

8040 Cranes, in general 

8050 Lifting Magnets 

8060 Lifting Magnet Equipment 

18.03. Vehicles and Transport Containers 

8080 Container Parking Systems 

8090 Fork Lift Trucks, in general 

8100 Fork Lift Trucks for Fluid Transports 

8110 Equipment for Melt Transport 

18.04. Bunkers, Siloes and 

Accessories 

8140 Linings 

8145 Big-bag Removal Systems 

8150 Hopper Discharger and 

Discharge Chutes 

8160 Hoppers 

8170 Conveyor Hoses 

8190 Silos 

8200 Silo Discharge Equipment 

8210 Silo Over-charging Safety Devices 

8218 Wearing Protection 

8220 Vibrators 

18.05. Weighing Systems and Installations 

8230 Charging and Charge 

Make-up Scales 

8240 Metering Scales 

8250 Monorail Scales 

8260 Crane Weighers 

8280 Computerized Prescuption Plants 

8290 Scales, in general 

18.07. Handling Technology 


8340 Industrial Robots 

8350 Industrial Robots, Resistant to Rough 

8364 Chipping Plants with Robots 

18.08. Fluid Mechanics 

8365 Pumps 

8367 Compressors 

18.09. Storage Systems, Marshalling 


18.10. Components 



19.01. Engines for Patternmaking 

and Permanent Mold 

8380 Band Sawing Machines for 

Patternmaking 

8400 CAD/CAM/CAE Systems 

8410 CAD Constructions 

8420 CAD Standard Element Software 

8423 CNC Milling Machines 

8425 Automatic CNC Post-Treatment 

Milling Machines 

8430 CNC Programming Systems 

8440 CNC, Copying, Portal and Gantry 

Milling Machines 

8470 Dosing Equipment and Suction 

Casting Machines for the Manufacture 

of Prototypes 

8480 Electrochemical Discharge Plants 

8490 Spark Erosion Plants 

8500 Spark Erosion Requirements 

8510 Development and Production of 

Lost-Foam Machines 

8520 Milling Machines for Lost-Foam 

Patterns 

8522 Hard Metal Alloy Milling Pins 

8525 Lost-Foam Glueing Equipment 

8527 Patternmaking Machines 

8576 Rapid Prototyping 

8610 Wax Injection Machines 

19.02. Materials, Standard Elements 

and Tools for Pattern- and 

Diemaking 

8630 Thermosetting Plastics for Patternmaking 

8650 Toolmaking Accessories 

8660 Milling Cutters for Lost-Foam 

Patterns 

8670 Free-hand Milling Pins made of 

Hard Metal Alloys and High-speed 

Steels 

8675 Hard Metal Alloy Milling Pins 

8680 Adhesives for Fabrication 

70

8690 Synthetic Resins for Patternmaking 

8700 Plastic Plates Foundry and Patternmaking 

8705 Lost-Foam Tools and 

Patterns 

8710 Patternmaking Requirements, in 

general 

8720 Patternmaking Materials, in general 

8730 Pattern Letters, Signs, Type Faces 

8740 Pattern Dowels (metallic) 

8750 Pattern Resins 

8760 Pattern Resin Fillers 

8770 Pattern Plaster 

8780 Pattern Gillet 

8790 Lumber for Patterns 

8800 Pattern Varnish 

8810 Pattern-Plate Pins 

8820 Pattern Spaddles 

8830 Standard Elements for Tools and 

Dies 

8840 Precision-shaping Silicone 

8846 Rapid Tooling 

19.03. Pattern Appliances 

8880 CNC Polystyrol 

Patternmaking 

8890 Development and Manufacture of 

Lost-Foam Patterns 

8900 Moulding Equipment 

8910 Wood Patterns 

8930 Core Box Equipment for Series 

Production 

8940 Resin Patterns 

8960 Metal Patterns 

8970 Pattern Equipment, in general 

8980 Pattern Plates 

8985 Pattern Shop for Lost-Foam 

Processes 

9000 Stereolithography Patterns 

9010 Evaporative Patterns for the Lost- 

Foam Process 

19.04. Rapid Prototyping 

9021 Design 

9022 Engineering 

9023 Hardware and Software 

9024 Complete Investment Casting 

Equipment for Rapid 

Prototyping 

9025 Pattern and Prototype 

Making 

9026 Rapid Prototyping for the Manufacture 

of Investment Casting 

Patterns 

9027 Integrable Prototypes 

9028 Tools 

9029 Tooling Machines 


20.01. Control and Adjustment Systems 

9030 Automation and Control for Sand 

Preparation 

9040 Automation 

9042 Software for Production Planning 

and Control 

9050 Electric and Electronic Control 

9080 Equipment for the Inspection of 

Mass Production 

9090 Load Check Systems for Recording 

and Monitoring Energy Costs 

9120 Control Systems and 

Automation, in general 

9130 Control Systems, in general 

9160 Switch and Control Systems 

20.02. Measuring and Control 

Instruments 

9165 Automatic Pouring 

9166 Compensation Leads 

9185 Contactless Temperature Measurement, 

Heat Image Cameras 

9190 Leakage Testing and Volume 

Measuring Instruments 

9210 Flow Meters 

9220 Flow control Instruments 

9230 Immersion Thermo Couples 

9240 Moisture Controller 

9250 Level Indicator 

9280 Bar Strein Gauge 

9301 In-Stream Inoculation Checkers 

9302 In-Stream Inoculant Feeder 

9306 Calibration and Repair Services 

9310 Laser Measurement Techniques 

9320 Multi-coordinate Measuring 

Machine 

9330 Measuring and Controlling Appliances, 

in general 

9335 Measuring and Controlling Appliances 

for Fully Automatic Pouring 

9345 Positioning Control 

9350 Pyrometers 

9370 Radiation Pyrometers 

9375 Measuring Systems for Nuclear 

Radiation (receiving inspection) 

9376 Measuring Systems for Radioactivity, 

Incoming Goods‘ Inspection 

9380 Temperature Measurement 

9382 Temperature Control Units 

9385 Molten Metal Level Control 

9390 Temperature Measuring and 

Control Devices 

9391 Thermoregulator 

9395 Molten Metal Level Control 

9400 Thermal Analysis Equipment 

9410 Thermo Couples 

9420 Protection Tubes for Thermocouples 

9425 In-stream Inoculant Checkers 

9430 Heat Measuring Devices 

9433 Resistance Thermometers 

20.03. Data Acquisition and 

Processing 

9438 Automation of Production- and 

Warehouse-Systems 

9440 Data Logging and Communication 

9445 Business Intelligence 

9450 Data Processing/Software Development 

9456 ERP/PPS - Software for Foundries 

9470 EDP/IP Information and Data 

Processing 

9480 Machine Data Logging 

9484 Machine Identification 

9490 Data Logging Systems 

9500 Numerical Solidification Analysis 

and Process Simulation 

9502 Numerical Solidification Simulation 

and Process Optimization 

9504 ERP - Software for Foundries 

9506 Process Optimization with EDP, Information 

Processing for Foundries 

9510 Computer Programmes for Foundries 

9520 Computer Programmes and Software 

for Foundries 

9522 Simulation Software 

9523 Software for Foundries 

9525 Software for Coordinate 

Measuring Techniques 

9527 Software for Spectographic Analyses 

9530 Statistical Process Control 

9540 Fault Indicating Systems, 

Registration and Documentation 

20.04. Process Monitoring 

9541 High Speed Video 


21.01. Testing of Materials and 

Workpieces 

9548 Calibration of Material Testing 

Machines 

9550 Aluminium Melt Testing 

Instruments 

9554 Acoustic Materials Testing 

9555 Acoustic Construction 

Element Testing 

9560 CAQ Computer-Aided Quality 

Assurance 

9564 Image Documentation 

9580 Chemical Analyses 

9585 Computerized Tomography, CT 

9586 Core Gas - System for Measurement 

and Condensation 

9587 Die Cast Control 

9589 Natural Frequency Measuring 

9590 Endoscopes 

9600 Dye Penetrants 

9610 Instruments for 

Non-destructive Testing 

9620 Hardness Testers 

9630 Inside Pressure Testing Facilities 

for Pipes and Fittings 

9645 Calibration of Material Testing 

Machines 

9650 Low-temperature Source of 

Lighting Current 

9670 Arc-baffler 

9678 Magna Flux Test Agents 

9680 Magnetic Crack Detection Equipment 

9690 Material Testing Machines and 

Devices 

9695 Metallographic and Chemical 

Analysis 

9696 Microscopic Image Analysis 

9697 Surface Analysis 

9700 Surface Testing Devices 

9710 Testing Institutes 

9719 X-ray Film Viewing Equipment and 

Densitometers 

9720 X-Ray Films 



9730 X-Ray Testing Equipment 

9740 Spectroscopy 

9750 Ultrasonic Testing Equipment 

9755 Vacuum Density Testing Equipment 

9758 UV-Lamps 

9759 UV Shiners 

9760 Ultraviolet Crack Detection Plants 

9765 Hydrogen Determination Equipment 

9770 Material Testing Equipment, in 

general 


9800 Inside Pressure Measuring for 

Tools 

9836 Devices for Testing of Materials, 

non-destructive, in general 

9838 NDT Non-destructive Testing of 

Materials 

9840 NDT X-ray Non-destructive Testing 

of Materials 

9850 Tensile Testing Machines 

22 Analysis Technique and Laboratory Equipment 

10000 Sample Preparation Machines 

10010 Quantometers 

10018 X-Ray Analysis Devices 

10020 Spectographic Analysis Devices 

10022 Certified Reference Materials for 

Spectrochemical and -scopic 

Analysis 

10040 Cut-off Machines for Metallography 

9860 Analyses 

9865 Image Analysis 

9880 Gas Analysis Appliances 

9890 Carbon and Sulphur 

Determination Equipment 

9900 Laboratory Automation 

9910 Laboratory Equipment, Devices, 

and Requirements, in general 

9920 Laboratory Kilns 

9930 Metallographic Laboratory 

Equipment 

9940 Microscopes 

9948 Optical Emission Spectrometers 

9950 Microscopic 

Low-temperature Illumination 

9955 Continuous Hydrogen Measurement 

9960 Polishing Machines for Metallography 

9970 Sampling Systems 

9980 Sample Transport 

23 Air Technique and Equipment 

23.01. Compressed Air Technique 

10050 Compressed Air Plants 

10060 Compressed Air Fittings 

10070 Compressed Air Tools 

10080 Compressors 

10100 Compressor Oils 

23.02. Fans and Blowers 

10120 Fans, in general 

23.03. Ventilators 

10150 Axial Ventilators 

10160 Hot-gas Circulating Ventilators 

10170 Radial Ventilators 

10180 Ventilators, in general 

23.04. Other Air Technique 

Equipments 

10188 Waste Gas Cleaning 

10190 Exhausting Plants 

10192 Exhaust Air Cleaning for Cold-Box 

Core Shooters 

10220 Air-engineering Plants, in general 

24 Environmental Protection and Disposal 

10230 Environmental Protection and 

Disposal 

10231 Measures to Optimize Energy 

10232 Fume Desulphurization for Boiler 

and Sintering Plants 

10235 Radiation Protection Equipment 

24.01. Dust Cleaning Plants 

10240 Extraction Hoods 

10258 Pneumatic Industrial Vacuum 

Cleaners 

10260 Pneumatic Vacuum Cleaners 

10270 Equipment for Air Pollution Control 

10280 Dust Cleaning Plants, in general 

10290 Gas Cleaning Plants 

10300 Hot-gas Dry Dust Removal 

10309 Industrial Vacuum Cleaners 

10310 Industrial Vacuum Cleaners 

10320 Leakage Indication Systems for 

Filter Plants 

10340 Multicyclone Plants 

10350 Wet Separators 

10360 Wet Dust Removal Plants 

10370 Wet Cleaners 

10380 Cartridge Filters 

10400 Pneumatic Filter Dust Conveyors 

by Pressure Vessels 

10410 Punctiform Exhausting Plants 

10420 Dust Separators 

10430 Vacuum Cleaning Plants 

10440 Dry Dust Removal Plants 

10450 Multi-Cell Separators 

10458 Central Vacuum Cleaning Plants 

10460 Cyclones 

24.02. Filters 

10470 Compressed Air Filters 

10490 Dedusting Filters 

10500 Filters, in general 

10510 Filter Gravel 

10520 Filter Materials 

10530 Filter Bags/Hoses 

10550 Fabric Filters 

10560 Air Filters 

10570 Cartridge Filters 

10580 Hose Filters 

10585 Electro-Filters 

10590 Air Filters 

10610 Fabric Filters 

24.03. Waste Disposal, 

Repreparation, and Utilization 

10618 Waste Air Cleaning 

10620 Waste Water Analyzers 

10630 Waste Water Cleaning and -Plants 

10640 Clean-up of Contaminated Site 

10646 Used Sands, Analysing of Soils 

10650 Waste Sand Reutilization and 

Reconditioning 

10655 Amine Recycling 

10660 Foundry Debris-conditioning Plants 

10680 Soil Clean-up 

10690 Briquetting Presses 

10695 Briquetting of Foundry 

Wastes/Filter Dusts 

10700 Disposal of Foundry Wastes 

10702 Hazardous Waste Disposal 

10705 Bleeding Plants 

10710 Reconditioning of Foundry Wastes 

10720 Ground Water Cleaning 

10740 Dross Recovery Plants 

10760 Cooling Towers 

10770 Cooling Water Processing Plants 

10780 Cooling Water Treatment 

10810 Post-combustion Plants 

10830 Recooling Systems 

10840 Recycling of Investment Casting 

Waxes 

10850 Slag Reconditioning 

10870 Waste Water Cooling Towers 

10880 Scrap Preparation 

10890 Transport and Logistic for Industrial 

Wastes 

10900 Rentilization of Foundry Wastes 

10910 Rentilization of Furnace Dusts and 

Sludges 

10920 Roll Scale De-oilers 

10940 Rentilization of Slide Grinding 

Sludges 

25 Accident Prevention and Ergonomics 

10960 Health and Safety Protection 

Products 

10970 Asbestos Replacements 

10990 Ventilators 

10993 Fire Protection Blankets and 

Curtains made of Fabrics 

10996 Fire-extinguishing Blankets and 

Containers 

11020 Heat Protection 

11025 Heat-Protection Clothes and Gloves 

11030 Climatic Measurement Equipment 

for Workplace Valuation 

11040 Protection against Noise 

11050 Light Barriers 

11060 Sound-protected Cabins 

11070 Sound-protected Equipment and 

Parting Walls 

11080 Vibration Protection 


26.01. Plants, Components, and 

Materials 

11100 Concreting Plants 

11102 Devellopping and Optimizing of 

Casting Components 

11118 Vibration Technology 

26.02. Industrial Commodities 

11120 Joints, Asbestos-free 

72

11125 Sealing and Insulating 

Products up to 1260 °C 

11130 Dowels 

11150 Foundry Materials, in general 

11155 Heat-protecting and Insulating 

Fabrics up to 1260 °C 

11160 Hydraulic Oil, Flame-resistant 


11170 Signs for Machines 

11175 Fire-proof Protection Blankets, 

-mats, and -curtains 

11180 Screen and Filter Fabrics 

26.04. Job Coremaking 

11182 Inorganic Processes 

11183 Hot Processes 

11184 Cold Processes 


11186 Ordered Research 

11190 CAD Services 

11200 Interpreters 

11202 Diecasting, Optimization of Mould 

Temperature Control 

11205 EDP Consulting 

11208 Wage Models 

11210 Emission, Immission, and Workplace 

Measurements 

11211 E-Business 

11212 eProcurement 

11213 Technical Literature 

11215 Investment Casting Engineering 

11220 Foundry Consulting 

11230 Foundry Legal Advice 

11240 Lean Foundry Organization 

11250 Foundry Planning 

11252 Greenfield Planning 

11253 Casting, Construction and Consulting, 

Optimizing of Mould Core 

Production and Casting Techniques 

11260 Nuclear Engineering Consulting 

11278 Customer Service for Temperature 

Control Units and Systems 

11280 Customer Service for 


11283 Jobbing Foundry 

11286 Efficiency of Material 

(Consulting) 

11290 Management of Approval 

Procedures 

11291 Management Consulting 

11292 Machining 

11293 Metallurgical Consulting 

11294 Patinating 

11295 Human Resources Services 

11296 Personnel Consulting 

11298 Process Optimization 

11299 Testing Status and Safety Labels 

11300 Rationalization 

11301 M&A Consulting 

11303 Recruitment 

11305 Centrifugal Casting Engineering 

11310 Simulation Services 

11320 Castings Machining 

11325 Steel Melting Consulting 

11330 Technical Translation and Documentation 

11336 Environmental Protection Management 

Systems (Environmental 

Audits) 

11339 Restructuring 

11340 Environmental Consulting 

11342 Business Consultancy 

11343 Leasing of Industrial Vacuum 

Cleaners 

11345 Heat Treatment 

11346 Associations 

11360 Material Consulting 

11370 Material Advices 

11380 Time Studies 

11382 Carving 

28 Castings 

11387 Aluminium Casting 

11389 ADI 

11390 Aluminium Pressure Diecasting 

11400 Aluminium Permanent Moulding 

(Gravity Diecasting) 

11410 Aluminium Sand Casting 

11420 Billet Casting 

11430 Cast Carbon Steel, Alloy and 

High-alloy Cast Steel 

11440 Non-ferrous Metal Gravity Diecasting 

11450 Pressure Diecasting 

11460 High-grade Investment Cast Steel 

11462 High-grade Steel Casting 

11470 High-grade Steel Castings 

11472 High-grade Centrifugal Cast Steel 

11480 Ingot Casting 

11485 Castings 

11489 Rolled Wire 

11490 Grey Cast Iron 

11492 Large-size Grey Iron Castings 

11496 Direct Chill Casting 

11498 Art Casting 

11499 Light Metal Casting 

11501 Magnesium Pressure 

Diecasting 

11510 Brass Pressure Diecasting 

11520 Non-ferrous Metal Sand Casting 

11525 Prototype Casting 

11530 Sand Casting SAND CASTING 

11539 Centrifugal Casting 

11540 Spheroidal Iron 

11547 Spheroidal Graphite Cast Iron 

11550 Steel Castings 

11552 Continuously Cast Material 

11553 Thixoforming 

11555 Full Mold (lost-foam) Casting 

11558 Rolls 

11560 Zinc Pressure Diecasting 

11570 Cylinder Pipes and Cylinder Liners 

29 By-Products 

11580 Sporting Field Sands 


11700 Mold Filling and Solidification 

Simulation 

11800 Simulation Programmes for 

Foundry Processes 

11820 Software for Foundries 

31 Foundries 

11850 Foundries, in general 

31.01. Iron, Steel, and Malleable-Iron 

Foundries 

11855 Iron Foudries 

11856 Steel Foundries 

11857 Malleable-Iron Foundries 

31.02. NFM Foundries 

11860 Heavy Metals Foundries 

11861 Die Casting Plants 

11862 Light Metal Casting Plants 

11863 Permanent Mold Foundry 

31 Additive manufacturing / 3-D printing 


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May, 13-16, 2020, Shanghai, China 

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Hitachi High-Tech Analytical Science GmbH, 

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Lucky -Winsun Enterprise Ltd., 

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PREVIEW/IMPRINT 

Die casting companies from 

all over Europe are once again 

expected at the upcoming 

EUROGUSS trade fair in January. 

Photo: Messe Nürnberg 

Preview of the next issue 

Selection of topics: 

M. Vogt; R. Piterek: Follow-up report from EUROGUSS in Nuremberg 

More than 700 exhibitors are exhibiting in January 2020 at the Nuremberg fair – most likely again with an international exhibitor 

share of more than 50 percent. Thanks to its steady growth, EUROGUSS has developed into a technology platform that sets 

global standards. Our follow-up report highlights innovations and business developments from the world of die casting. 

K. Kerber; A. Marks: Increasing efficiency in die casting foundries with digitization 

For die casting foundries with their demanding production process, achieving maximum production efficiency is a constant 

task. With smartfoundry.solutions, Oskar Frech offers customized digitizing solutions. 

E. Potaturina; K. Seeger: Coatings for additively manufactured molds and cores 

3-D printing allows designers unprecedented degrees of freedom in shaping molds and cores. However, as printed cores differ 

markedly from shot ones in some important properties, special demands are placed on the coatings used. 

Imprint 

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ISSN 0935-7262 

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CPT International 4/2019

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