High Pressure Moulding

Crescent Foundry's has a state of the art plant with Sinto^® Flaskless High Pressure Molding Line. The location of the plant is Vadodara, Gujarat, spanning over an area of 160,000 sq. meters and an overall projection of 4 plants across 40 acres of land that has been acquired.
The first plant has been operational since June 2014 with a melting capacity of 25,000 tons per annum. The materials are Grey/Ductile Iron with a Maximum Bunch Weight of 60 kg.
The future projection is to have 3 more plants with a further 75,000 tons per annum capacity.

The Machine

The SINTO Edge: The SINTOKOGIO GROUP of Japan is on the world's largest foundry machine manufacturers with 42 companies in 10 countries. After extensive evaluation, it has been concluded that Sinto offers the best machine for horizontal flask-less molding in terms of productivity, quality, flexibility and support.

The Advantage

Production Machines

Productivity

171 sand molds per hour i.e. one complete mold in 21 seconds
Total uptime exceeds 98%.

Flexibility

Small/large/multiple cores can be set in cycle time
Pattern changing time within 2 mins

Quality

Maximum mismatch of two halves of the castings does not exceed 0.1 mm (0.0039 in).
Due to pouring in a horizontal mold, defects due to ferrostatic pressure issues are minimized

Cost

Molding sand consumption can be minimized due to variable mold thickness between 180 to 250mm.
It does not use flasks, which avoids a need of their transporting, storing and maintaining.
It is fully automatic and requires only one monitoring operator, which reduces labor costs.
Automatic casting cleaning and abrasive blasting machines placed in-line to reduce manual work

The Process

Our High Pressure Molding Process consists of mainly the FCMX III and mold transporting conveyor. A molding sand mixture, usually green sand or bentonite, is blown into a rectangular steel chamber using compressed air. The molding sand is then squeezed against two patterns, which are on the two ends of the chamber. After squeezing, one of the chamber plates swings open and the opposite plate pushes the finished mold onto a conveyor. Finally, if any cores are there, they are set into the mold cavity while the next mold is being prepared. The cycle repeats until a chain of finished molds butt up to each other on the conveyor.

The molds are then filled with molten metal and placed on a cooling conveyor, which moves at the same pace as the fabrication conveyor. At the end of the conveyor the solidified castings are separated from the molds and processed further, while the sand is directed to the sand preparation plant for reconditioning and reuse in the next cycles of the Sinto High Pressure Molding Process.