Released on November 23, 2009

Ferrous caster Urick Foundry, Erie, Pa., recently completed the installation of several new pieces of equipment that amount to an entirely new sand system, according to a company spokesperson.

“Our old dust collection system was from the 70s, and our drums were both almost worn out, so they were due to be replaced,” said Dan Mayton, the company’s foundry director.

In addition to general wear concerns, the ductile iron caster also has recently begun making larger castings than the system was originally designed for. The company, which produces on average 14-15 thousand tons of castings per year, wanted to be able to produce quality large parts without having to heat treat them. The solution was a new drum that separates the company’s castings from the return sand immediately after shakeout. Both materials—the castings and the sand—benefit from the immediate separation.

“It’s a whole different concept for us,” Mayton said.

In addition to the drums, the company has replaced its dust collection system and added a new sand cooler. The sand system upgrade is the latest in a series of improvements Urick Foundry has made since 2003. The installation, which was approved in 2008, was begun on Oct. 23, and the new system launched on Nov. 16. The upgrade required that the facility be closed for three weeks, according to Mayton.

“It’s actually a good time to gut the place, because all of the contractors were available,” he said. “There’s a lot to do when you are dealing with replacing all those different systems.”