DIDION Streamlines Sand Separation in Progressive Foundry Expansion

Goals

Foundry Expansion

Progressive Foundry located in Perry, IA, a producer of gray and ductile iron castings, completed a multi-million multi-phase foundry expansion. This expansion included a new core room building, new employee center, new metallurgical lab, new office building, and an update to its shakeout system. The shakeout system upgrade was prompted by the continued growth of the foundry and the downstream equipment needed to meet the capabilities of the new molding lines that have been upgraded throughout the years. The layout, age of the equipment, as well as safety and dust emissions were all factors that led to this shakeout expansion.

Challenge

Selecting the Right Equipment

Josh Magill, Plant Engineer, researched several different types of equipment and solutions for his shakeout portion of the expansion. These included rotary and vibratory options from traditional shakeouts to vibratory drums to rotary drums. In the end Progressive decided on a DIDION Rotary Media Drum to handle their sand separation and casting cleaning needs. “DIDION’s reputation ultimately led us to our decision,” stated Josh. “Every foundry we visit has a DIDION Rotary Media Drum. The equipment is well-built and made to last.”

DIDION’s reputation ultimately led us to our decision. Every foundry we visit has a DIDION Rotary Media Drum. The equipment is well-built and made to last.

Josh Magill, Plant Engineer, Progressive Foundry

Solution

MD-200 Rotary Media Drum

DIDION offered the most efficient approach by combining shakeout, sand blending, double sand screening, casting cleaning and cooling with the MD-200 Rotary Media Drum. The media cleans the casting, as well as provides a media cushion for the castings which allows Progressive to now bypass a few, if any, castings with the reduced scrap rates from the DIDION. Sand carryover has also been dramatically reduced over the old shakeout system. Josh said, “We are very happy with the reduction in carryover sand. There is significantly less time spent cleaning sand piles around the blast cleaning area.”