DIDION Helps Austin Foundry Uncover Savings in the Sand Casting Process
Key Takeaway
DIDION revolutionized Austin Foundry Corp’s operations by significantly enhancing efficiency, slashing disposal costs, and elevating reclaimed material quality – discover our approach.
Goals
Efficiency, Savings, Sustainability
Austin Foundry Corp., of Sheboygan WI, is a gray and ductile iron jobbing shop that has been producing quality castings ranging in size from one pound to 5,000 pounds for a wide variety of industries since 1946. Their molds are chemically bonded with Furan and some Pepset binders. “We first considered a sand reclamation system a few years back, but with the recent downturn in the economy and our ever-increasing costs, becoming even more cost efficient became a priority.
The cost savings potential of a DIDION Sand Reclamation System became obvious”, says Sean Girdaukas, Vice President of AUSTIN FOUNDRY CORP.
Challenge
Offset Increasing Operation Costs
“We sent sand samples to DIDION for testing, using their Rotary Lump Crusher/Sand Reclaimer system. DIDION’S patented design crushed the hard lumps, scrubbed the binder off the sand grains, screened the sand twice, recirculated the screen overs, and separated tramp metal. After evaluating the test results and their proposal, we purchased and installed the DIDION Sand Reclamation System. Installation was fast and easy. We are very pleased with the quality of the reclaimed sand and the system is extremely reliable.”
In the first eight months of use, we reclaimed over four million pounds of spent sand which would previously have been sent to a landfill.
Sean Girdaukas, Vice President of Austin Foundry Corp.
Solution
The Rotary Sprue Cleaner / Crusher
“In the first eight months of use, we reclaimed over four million pounds of spent sand which would previously have been sent to a landfill. We were able to dramatically reduce our new sand purchases and disposal costs. In addition, we have been able to cut back on binder and catalyst usage with no ill effect. We anticipate saving a quarter million dollars annually. Helping the environment is saving us money,” concludes Girdaukas.
The team at Austin Foundry was excited to reclaim a buried treasure. Turn a waste stream into a revenue stream and keep the EPA and DNR inspectors happy.
Results
Annual Savings of $250,000
Advantages and features of the DIDION Sand Reclamation System:
Fastest payback
Patented multi-chamber design combines lump crushing, sand scrubbing, sand conditioning, dual sand screening, and metal separation for the fastest payback.
Up to 97% yield
The time-tested design has the best performance/highest yield (up to 97%) in the industry.
Reduced waste
Significant savings from reduced binder consumption, lower new sand purchases, and minimal disposal costs.
Lower costs
Additional savings from conditioned and higher quality reclaimed sand (which is more uniform/consistent) lowers finishing costs and reduces casting scrap.
Custom sizing
The patented design has the lowest operating cost per ton in the industry worldwide, with system sizes from 1-100 TPH.
Cleaner air
Highly efficient air-wash separation reduces binder, dust, debris, and excess fines.
Revolution in action.
See more success stories from foundries and recycling plants.