Magaldi Power SpA entered the Turkish metal casting market several years ago, successfully positioning itself as a trusted technology partner for the country’s foremost foundries.
Recently, Dirikanlar Otomotiv San. Tic. Ltd. Şti engaged Magaldi to provide a comprehensive solution for mold conveying, casting cooling, degating and sorting at their iron foundry in Aksaray.
Magaldi custom-designed a Superbelt® conveyor and a Magaldi Casting Cooler (MCC®) to meet the foundry’s specific operational requirements.
The Superbelt® conveyor moves 78 tons per hour of molds from the punch-out to the shakeout, ensuring reliable and safe transportation. Its patented double-wire mesh provides redundancy for continuous, trouble-free operation, even when transporting sand and molds at a temperature of 700°C (1,292 °F). The unique method of connecting the pans to the mesh belt allows all components to freely expand in any direction, enabling the conveyor to withstand temperatures of up to 1100 °C (2,012 °F) while preventing permanent deformation and preserving abrasion resistance.
Additionally, the conveyor's smooth and vibration-free movement minimizes silica dust generation, while covers prevent emissions. This ultimately improves worker safety and reduces housekeeping costs.
Downstream of the shake-out, the MCC® cooling system comes into play. The system consistently cools castings from 550 °C (1,022 °F) to 100 °C (212 °F) through a controlled stream of ambient air that prevents thermal shocks and other microstructural defects on castings, ensuring top-tier quality.
Upon exiting the cooling tunnel, operators handle degating and sorting tasks directly on the belt. The absence of vibrations, the ergonomic belt design, and the noise level below 75 dB(A) significantly mitigate the risk of injuries, contributing to a safer and more productive work environment.
This comprehensive solution, which went live in July, has significantly improved Dirikanlar's operational efficiency and helped Magaldi reach new heights in the dynamic Turkish metal casting market.
