Manish Kothari Managing Director
Rhino Machines Pvt. Ltd.
1. Sand Mixing & Cooling 2. Sand Control 3. High Pressure Moulding 4. Compact Sand Plant 5. Sand Reclamation
The need to produce castings of improved quality, amongst other things, requires disadvantages related to hot sand, quite simply by cooling it.
For that, traditionally the foundries install silos.
reducing the
a cooler between the shakeout and the storage of sand into the
By installing in the circuit an additional machine - the cooler- and its accessories, the sand-preparation plant becomes more complicated and thus more expensive to install and to use it.
This new machine, mixer-cooler, is produced under the name of Mixer Cooler- Series RMC. This made it possible to return to extremely simple well to the installation as in industrial exploitation.
and economic concepts of sand-preparation plant as
The results obtained in various foundries as well in Europe as in Asia or Latin America, show clearly than the sand is not only well cooled but also that it is prepared better, which is an important advantage for the quality of
the moulding and thus of the castings produced . This new concept of ultra
compact sand plant generates very important economics on all the levels
Prepared Sand Temperature Sand Consistency System Sand Properties
•Input Sand from 20 to 75 °C •Output Sand 32-45 °C at 45°C Ambient •Compactibility on Moulding Machine +/- 2 points •Controlled Dead Clay %age within limits. Integrated controlled fines reintroduction into mixer.
New Sand Addition
•Substantial Reduction due to Removal of Dead Clay
Bentonite Addition
•. Nearly 40% reduction in consumption of Bentonite
Power Consumption Surface Finish 62 54 55 54 48 44 39 41 42 43 44 33 3231 30 312733283831 35 25 25
•Overall Power Consumed reduced and optimized
•Velvet Touch Sand produced improved the casting surface finish substantially
Control
• Compactibility
Manage
• Green Compressive Strength • Additves Addition
Monitor
• Shiftwise/Monthly/Yearwise Data on: Production, Variation, Consumptions, Averages
Qualitative Advantage Tangible Benefits Direct Savings ROI
• Surface Finish • Productivity • Management Information System • Reduction in Sand Related Rejections • Reduction in Weight due to Controlled Moisture • Improvement in Productivity • Sand Related Rejection – reduced by nearly 50% • Weight variation saving – approx 0.5% • Manpower – 50% Reduction (manless operation) • 12-24 Months payback on Direct Investment • On Rejection @ Rs 30k/MT • On Weight Reduction @ Rs30k/MT • On Manpower Rs 15k/Month
Foundry User Needs
Reduced dependence on Skilled Personnel
•Consistent Quality •Dimensions •Surface Finish •Casting Defects •Weight Variation
•Lower Production Costs •Lower Capital Investment •Lower Energy Consumption •Higher production with lesser manpower •Lower Maintenance & Operational Costs •Lesser Space Requirements •Reduced Machining Allowance •Reduced Fettling Requirements
Quantitive Results
The Process
Rhino’s Solution to meet the Customer Need • High Pressure Moulding – specific squeeze pressure 8-12 kg/cm2 • Squeezing of Pattern into Sand • Weighed and Controlled Sand Quantity • Single Point Sand Filling • One Machine for Cope & Drag Moulding • USER FEEDBACK : Pipe Fitting Casting Producer : • Castings within +/- 0.5 mm • 450 moulds in 10 hours with 10 people for sand, molding, pouring and knockout • Cost per mould Rs 14 for direct workmen • Weight variation +/- 3 gms in 239 gms casting i.e. 1.29% against 2.36% in same pattern on JSQ • Calculated weight in drawing and that in FM is same, does not need correction • Able to deliver required quantity in required time, and able to retain customers, dependency on labour shortage eliminated in “holiday” period • Viable with bunch weight 3 kgs also!!
Typical Comparison of Available Solutions for Moulding Solutions – SME/SMB Foundries Typical Comparison of Moulding Solutions
FM
JSQ
Flaskless
Avg Moulding Speed
40
40
100
Working Hrs./Day
20
20
20
Days/Year
288
288
288
Moulds per Day
800
800
2,000
20,000
20,000
50,000
Power Cost Rs./Mould
2.23
3.72
4.46
Moulding Manpower Cost/Mould
9.45
14.85
11.34
Interest Cost Rs./Mould
5.34
3.59
6.41
Total Cost / Mould
17.03
22.15
22.22
1.00%
0%
1.50%
25
25
20
0.25
0
0.3
Rate of Metal for Rejection
32
32
32
Saving per Mould in Rs/Mould
8
0
10
9.0
22.2
12.6
Moulds per Month Summary of Costs/Mould
Savings to Offset Costs Saving in Casting Rejection/Weight Avg Casting Wt/Mould Saving per Mould in kg/Mould
Net Cost per Mould after considering wt/rej saving
Evaluate and Invest Smartly with the Right Balance of Risk, Volume and Cost
Deliverables
The Compact Sand Plant Solution
• •
Economical, Manageable, Modular Plant
•
Minimum Power & Installed Machines – Minimum
• •
Lowest Foot Print and Height Combination
• •
Highest Return on Investment
•
Some Bench Marks of ECOFLEX Plant Shed Foot Print : 300 MT/500 m2 = 0.6 MT/m2
No Bucket Elevator – reduced maintenance, reduced pit, reduced dust generation Maintenance Order to Installation – 101 days for FM1 line, 121 days for FM2, 151 days for FM3 Enabling SME/SMB to Invest in Affordable Modern Technology
• • •
Installed Power – 135 kW/300 MT = 0.45 kW/MT Manpower 20 persons/ 300 MT = = 15 MT/Man/Month for Sand, Molding & Pouring
SAND REGENERATION SYSTEMS Solutions under License from FATA Aluminum
RESIN SAND
RESIN SAND
GREEN SAND RESIN SAND
GREEN SAND RESIN SAND
GREEN SAND
EASY REC 0,5 t/h
COMPACT REC 1 – 2,5 t/h
ECO REC 3 – 7 t/h
HOT REC 5 – 12 t/h
DRY ATTRITION 1–10 t/h
• • • •
REDUCED INVESTMENT EASY OPERATION LOW MAINTENANCE SMALL SPACE OCCUPATION
• • • •
REDUCED INVESTMENT HIGH ENERGY SAVING LOW MAINTENANCE SMALL SPACE OCCUPATION
• • • •
EASY OPERATION LOW MAINTENANCE FLEXIBLE OPERATION ENERGY SAVING
• • • •
HIGH EFFICIENCY HIGH PRODUCTIVITY FLEXIBLE OPERATION HIGH ENERGY SAVING
• • • •
HIGH EFFICIENCY HIGH PRODUCTIVITY FLEXIBLE OPERATION DEDICATED ENGINEERINGING
Sharing some pictures of Clean & Green ECOFLEX Foundry in Brazil With Fondarc Mixer Cooler & Compact Sand Technology If we dream, yes we can do it too!! We have the Technology ...are you ready?
THANK YOU
Green Sand Process Solutions
MULTIFLEX Prepared Sand Distribution
FM Series High Pressure Moulding
RMC Sand Mixer Cooler With Additives Dosing
Liquid Metal Handling
RTC –
Ladles, & Bi Rail
Online Sand Control ECOFLEX® Sand Plant with Sand Recirculation, Homogenising & Cooling
Mould Handling & Shake Out