Foundry technology

Quest. 1: Have you already carried out process optimisation with regard to material efficiency in your foundry?

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Quest. 2: Are you working on a continuous reduction of the energy deployment in your foundry operation? help

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The melting of metal and the holding of molten metal make up a substantial part of the energy consumption of a foundry. In many foundries, more energy is consumed to keep the metal in a molten state, as in the actual melting process.
In addition, significant amounts of energy are consumed in other areas than the metal provisioning. Foundries are as large consumers of compressed air. Other large energy consumers are likely high pressure die casting machines, which mainly hydraulic parts are also electrically operated. Sand and mould foundries can use hot core manufacturing processes, such as mask core and hot-box cores, that use gas or electricity for heating the boxes. The heating of die cast moulds, pans and oven linings may account for a significant part of total energy consumption.
The data from two foundry examples show, that the remaining foundry processes - except the melting and holding - are responsible for almost half of the energy consumption of a foundry. This includes activities with motors and drive equipment, compressed air, lighting, space heating and boiler systems. Energy efficiency measures should capture both areas - smelter and remainig processes. [UBA GI (2004). S. 263]

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Quest. 3: Do you regularly reduce the reject and reworking rates in your production? help

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Rework means all measures that are executed on a defective product, so a salable state is reached. Causes of rework consist for example in insufficient production documents, in unsafe manufacturing processes, improper handling of materials, components and products in manufacturing or transportation or inadequate packing.

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Quest. 4: Do you avoid or reduce wastes in your foundry works?

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Quest. 5: Do you reduce the quantity of waste sand during sand mould casting to a minimum? help

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Since foundries use sand intensively as inert base, the regeneration of sand is an essential aspect to consider the environmental impact. Environmental benefits and cost savings resulting from a reduction in the amount of sand to be deposited and the consumption of new primary sand [UBA GI (2004). S. 275].

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Quest. 6: Are you working on a continuous reduction of waste water creation in your foundry?

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Quest. 7: Do you already ensure that treatment is environmentally and raw material-friendly when storing your raw materials? help

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An environmentally friendly and resource-saving material storage includes the avoidance of soil and water contamination and the optimization of internal scrap circuits.

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Quest. 8: How are improvements in the process sequences in your company accepted and implemented by the staff? How does information exchange between the product development, manufacturing, engineering services and purchasing departments take place?

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