Manufacturing - Coremaking

"The shareholders commitment to having a state-of-the-art foundry has resulted in significant new investment in melting, moulding, coremaking and other equipment. The result - on time delivery of quality castings."

- Rob McBain
Laempe Cores
Laempe Cores
Since 1994 the majority of cores have been produced on two Laempe dual process cold box core centres for production of cores from ounces to over 60 lbs.
Core Box in Open Position
Core Box in Open Position
The Laempe core centre represents the pinnacle of core production technology. The fully computerized machines provide powerful operator interface and control to configure the core centre and displays an instruction sheet on how to mount the tooling. Vacuum is used to secure the tooling to the clamping cylinders and resin chemistry selection and composition is set by the computer.

Core Removal
Operator Removing Core
Tooling can be constructed from a wide range of materials such as wood, plastic, aluminum or cast iron. Tooling modifications are simple and are usually done utilizing plastic. The Laempe is not restricted to vertical parting only, in fact up to six piece core boxes can be run easily. This flexibility gives the casting designer a whole new set of options to work with.

Melting & Molding

Ancast utilizes high speed automated green sand moulding for production of castings. Small castings (0.5 to 40 lbs.) are produced on two 2016 B&P Matchblowmatics and are poured on Continumatic mould handling systems. Medium size castings (up to 100 lbs.) Are produced on a Hunter HMP 20E with a Vulcan Truflo mould handling system.

Large castings (up to 300 lbs.) Are produced on a Hunter HMP32E moulding machine and are poured on a rotary turntable.

Ancast melts with three coreless induction furnaces - two six ton capacity 1500 kW line frequency units and one six ton capacity 3000 kW variable frequency unit. Melting capacity is approximately 200 tons per day.

These furnaces are charged by a traveling car charging system with charge materials preheated by a 12 million BTU down fired preheater. Ductile iron treatment is carried out in enclosed tundish ladles.

Jose Castillo
Jose Castillo - Metallurgist
"Our metallurgical department in conjunction with well trained personnel utilize the latest technology to control our melting process, and to provide high quality castings to meet the customer's specifications."

Manufacturing - Equipment

    Charging, Melting and Pouring

  • 2 Inductotherm 1500 kW 60Hz Coreless Induction Furnaces - 6 ton capacities
  • 1 Inductotherm 3000 kW Coreless Induction Furnace --VIP Medium Frequency 6 ton capacity
  • 12 million BTU downdraft preheater
  • Travelling charging car
  • 4500 lb. Tundish treatment ladles
  • Kaltek lined powered vertical travel pouring ladles
  • Coremaking

  • 2 Laempe L20 cold box core centres - core capacities to 60 lbs.
  • Core Additive Feeder available to both Laempe Core machines
  • Various shell core machines with capacities from ounces to 100 lbs.
  • No bake core loop with capacity to hundreds of lbs.
  • Core Wash Station
  • Moulding

    Small Castings 0.5 -40 lbs.

  • 2 Beardsley & Piper Matchblowmatics 16 X 20 X 6/6 complete with automated mould handling systems
  • Midsize Castings 10 - 100 lbs.

  • 1 Hunter HMP 20E Moulding Machine 20 X 24 X 8/8 complete with a Vulcan Truflo mould handling system
  • Large Castings 100 - 300 lbs.

  • 1 Hunter HMP 32 E Moulding Machine 30 X 32 X 12/12 complete with pouring turntable and walking beam mould handling system
  • Mulling

  • 1 Beardsley & Piper 75B Speedmuller
  • 1 Beardsley & Piper 85B Speedmuller
  • 2 Rotary sand cooling drums
  • Shakeout

  • 1 Didion MD 100 rotary shakeout
  • 1 Didion RS 100 rotary shakeout
  • Cleaning, Finishing, Heat Treating

  • 1 - 34 cubic foot Tumblast
  • 1 - 14 cubic foot Tumblast
  • 1 - 72" table Wheelabrator
  • High Speed Grinders
  • Primer Paint Line
  • Computer controlled gas fired car bottom annealing oven
  • Laboratory

  • Metallography Lab complete with Baird FSQ Vacuum Spectrometer with As Cast capability
  • Green sand test lab
  • Dimensional Lab with Coordinate Measuring Machine
  • Pattern Shop