Branded as the System 3000, the technology advances include upgraded internal hardware components, a new operating system, new process control software, and extended measurement capability of core thermal analysis sampling technology. The System 3000 maintains SinterCast’s modular hardware format to provide installation flexibility for any metalcaster's layout and process flow, and is configurable for companies that produce CGI from pressurised pouring furnaces or by ladle pouring.

The new hardware platform is based on industrial computers with solid state hard drives to ensure operational robustness. The System 3000 also includes enhanced power disturbance filtering to protect against electrical brown-outs and power spike.

Operators interact with the system via a 19-in. touch screen display that is programmed in the local language and configured according to the preferences of each plant. The System 3000 also provides comprehensive hardware diagnostics and troubleshooting functions simply by connecting a laptop computer to one of the customer access serial ports.

The System 3000 is launched with the latest version of the SinterCast process control software, PCS 6.0, operating on a rugged XP embedded platform. The version PCS 6.0 software is the 61st software release issued by SinterCast since the introduction of the System 2000 process control system in use since 1999. The PCS 6.0 software provides improved operator friendliness and expanded access for customer engineers to independently configure the metallurgical software parameters and to perform maintenance. The results from each thermal analysis measurement are stored by the System 3000 and are available for automatic transfer to the quality control IT system for realtime
logging of series production data and traceability.

Following extensive field testing, SinterCast has also released a new version of its sampling cup as a part of the System 3000 technology package. Referred to as SP-05, the new sampling cup is based on an improved reactive coating that enhances the resolution of the patented Wall Reaction and simultaneously counteracts the influence of deleterious tramp elements that are becoming increasingly common in the raw material stream, particularly for casting facilities in the
developing world. As a result of the enhanced Wall Reaction, the SP-05 technology also extends the analysis capability toward higher carbon equivalent levels.

Together, SinterCast reports these improvements reinforce its ability to consistently control CGI series production within a narrow range at the low end of the ISO 16112 Standard 0-20% CGI
nodularity specification, where casting defects are minimized and thermal conductivity and machinability are optimised.

All of SinterCast’s new field activities since late-2008 have been conducted with the SP-05 Sampling Cup, and future System 3000 foundry installations will be commissioned with the SP-05 technology. Existing customers have the option to upgrade to the SP-05 sampling technology at any time.

In parallel with the System 3000 launch, SinterCast is also launching the new Mini-System 3000. The Mini-System 3000 uses the same sampling technology and software as the fully automated System 3000, but is based on a simplified hardware platform that has been specifically designed for CGI product development, prototyping and niche volume production. The Mini-System 3000 does not include an integrated wirefeeder, as most product development activities are based on a ladle size of less than 500 kg. Where appropriate, the metalcaster can source a separate wirefeeder and
manually input the magnesium and inoculant wire addition results provided on the operator display screen. All product calibrations developed using the Mini-System 3000 can be directly transferred to the fully automated System 3000 for series production.

“SinterCast’s third generation technology incorporates foundry production experience gained from the initial System 1000 process control system launched in 1996, the System 2000 launched in 1999, and an intensive R&D campaign conducted over the past 14 months” said Steve Wallace, operations director. “The new System 3000 platform has successfully undergone extensive full load simulation testing, corresponding to the continuous production of more than three million cylinder blocks under typical foundry production conditions. We look forward to supporting the future CGI needs of the foundry and automotive industries with this new platform.”

“Despite customer Quality Feedback ratings of more than 96% in 2008 and 2009, we strategically decided to turn the economic downturn into an opportunity by focussing our engineering resources on a comprehensive review of our deliverable technology” said Steve Dawson, President & CEO. “The resulting suite of System 3000 technologies provides a new base for our further development, ensuring that we continue to satisfy the needs of our foundry customers for flexibility, robustness, accuracy and independence.”