FOUNDRIES

The smart combination of a JOEST MD-8 series lifting and tipping device and a JOEST charging feeder not only ensures a smooth material flow, but also guarantees a high level of safety and durability.

At JOEST, we always focus on efficiency and reliability when it comes to successfully implementing complex projects. A current example of this is the full modernization of a green sand line at our long-standing partner Fritz Winter – and that in an impressively short time.

At JOEST, we take pride in optimizing our customers’ production with innovative technologies and customized solutions. A recent example is our collaboration with HYDROTEC Technologies AG, an internationally operating company with over 50 years of experience and a clear vision: to continuously improve.

We look back on a successful exhibition! The JOEST group was proud to be part of the EUROCAST booth – our Polish representation – at the Metal Expo in Kielce, and we would like to thank everyone who visited us at our stand!

Ankiros 2024 in Istanbul (September 19-21)has come to a successful close, and we would like to thank everyone who visited the stand of our Turkish representative 𝐄𝐗𝐏𝐄𝐑𝐓.

Exciting project for sustainability: the largest machines we’ve built to date – two massive 30-ton Charging Feeder. These machines play a critical role in reducing CO₂ emissions on a large scale.

JOEST delivered several types of machines from its product portfolio for castings for a customer‘s complete system. To simplify and enhance the original process of storing casting parts in boxes for the cooling process, a JOEST Casting Cooler was installed downstream the existing shakeout.

For foundry melt shops the challenges start at the beginning with charging cars. Generally used to provide scrap, virgin ore and alloys to the charge furnace, they must be designed around each customer’s particular type of materials, furnace interface and processes.

Bosch Rexroth is modernizing its existing process of emptying die-casting molds by implementing a new casting-sand separation and recovery plant. Once the casts are freed from their molds, they are separated from the sand which is processed and reused. The task for JOEST was very complex. The focus was on the emptying process of the molds and to break down the sand and clean it. The sand is then returned to the casting process. On site, the machines will be placed in a space that was previously occupied by a furnace. A large chamber in which the furnace used to stand, connects the factory floor to the basement.

For the optimization of the foundry and to improve the production process, the Bosch Rexroth AG in “Lohr am Main” is adding a third furnace to its automatic charging system which currently features two furnaces. For this project, a new furnace platform is being built in the neighboring building. The task for JOEST was to find a solution, so that the existing feed equipment for the furnace Charging Vehicles could be reused. The vehicles are fed with metal scraps and additive materials needed for the melting process, both of which are bound to their original location.

For a client from the foundry industry based in Croatia, JOEST designed and manufactured a Shakeout. Its frequency and oscillation angle can be adjusted electronically, and this design includes a downstream feeder with dual-lane discharge. The machines were delivered to Croatia during the second fiscal quarter of 2021. Commissioning is performed and overseen by JOEST and is planned for this summer. The client ‘s demand was to provide a reliable Shakeout that could handle a large spectrum of parts whilst maintaining a small form factor due to space limitations on site. The machine should separate as much sand as possible without damaging the casts made of gray cast iron and spheroidal graphite iron. The client’s molding plant type HWS EFA-SD 5 with molding boxes of 1000x920x650 mm produces a maximum of 80 molds per hour. Roughly 2000 different parts are produced, the heaviest weighing 300 kg.

Atik Metal, one of the largest and most modern foundries in Turkey, producing mainly for export, makes a new investment. The Project includes two new HWS molding plants, the according Eirich sand processing with vacuum mixers and two custom shakeouts followed by manipulator supported cast processing technology. Als Trennrinnen kommen 2×2 Trennrinnen mit elektronischer Schwingparametereinstellmöglichkeit zum Einsatz. Empfindliche Gussteile, die für die Behandlung auf einer Trennrinne nicht geeignet sind, können per Manipulator auf eine parallel verlaufende Softhandlingstrecke übersetzt werden. So werden Oberflächenschäden vermieden. Auf der nachgeschalteten Lese- und Sortierrinne wird mittels Manipulator Kreislaufmaterial vom Gussteil getrennt und dann auf eine Hängebahnstrahlanlage transferiert.

In June this year, JOEST delivered a customized solution for casted pan dosing to a German client. This specially designed alloy plant features a remarkable dosing precision for aggregates. The client’s demand was to achieve the best precision possible when dosing the two components manganese-iron and silicon-iron. The two hoppers are loaded with the aggregates by the client. Dosing feeders then feed the two container wagons. The wagons are pre-dosed to roughly 20 kg to speed up the actual dosing process. The downstream feeder, which can pivot by 90°, then feeds the material directly into the pouring stream. Depending on the aggregate, the system is designed to dose between 5 and 10 kg and each scale reaches a precision of up to 50 grams.

This year, JOEST manufactured a 42-meter-long Casting Cooler for a client. The cooler was designed as a mass compensated resonance machine for the shock-free cooling of truck motor blocks in a continuous production flow. It is located after a green sand molding plant that produces 60 parts an hour with a weight of up to 550 kg per piece. The Casting Cooler cools these motor blocks from 400 °C down to 100 °C. A radiation pyrometer measures the temperature of the parts. From a machine dynamics standpoint, the Casting Cooler is equipped with active, synchronized vibration dampers. They are sub resonantly harmonized and feature an eccentric slider-crank drive. Open at the feed and discharge ends, the machine has a near airtight hood that forms an ideal flow channel. The air injection nozzle creates a strong air flow through this channel. The counter flow principle enables a direct convective heat exchange between the casting parts and the cooling air, resulting in a shock-free cooling process.

In this year’s spring, JOEST delivered Lifting and Tipping Technology in the form of a Lift and Swivel Column to Leinefelde. The client requested a solution to automatically load and unload annealing ovens with Heson stackable containers. All the equipment was to be placed in a single cell and enclosed by a safety fence. JOEST designed and manufactured an ideal client solution using Lift-ing- and Tipping Technology as well as Magnetic- and Trough-Type-Feeders. The stacking containers are fed into the system on one side by the client. On the other side, the container filled with tempered parts can be removed. The entire loading and unloading process of the oven is fully automated. The container is docked to the load handling attachment of the Lift and Swivel Column, type MSH. The machine lifts the container over a JOEST Trough-Type-Feeder, turns by 180 °C and dips into the feeder as far as possible. Until the machine reaches its final position, the parts are held back by a hydraulic flap. Once the flap has opened, the machine slowly retreats, and a small unbalances motor helps with the residual discharge.

In late October 2020, after one year of planning and designing and additional ten months of construction, the Australian #JOESTeam could finally move into the long awaited new building. The building designed by Brooking Design Architects is state of the art and is designed according to the lean principles. Turning first soil was in December 2019 with the architect, the contractor Robert Biagioni Constructions and Ian Laws, Managing Partner of JOEST Australia. Construction work finished in August 2020 and the keys were handed to Ian Laws, allowing the preparations for the relocation to start. The company had worked successfully at the old facility in Sheffield Road, Welshpool for over 15 years. Especially in the mining industry, the rising demand for larger machines required a new facility after the old one exceeded its capacities. The new facility is located in a giant logistic park at Coldwell Road. This new location enables faster and more efficient manufacturing of machines and also helps meet the clients’ rising demands.

For a client from the foundry industry based in Croatia, JOEST designed and manufactured a Shakeout. Its frequency and oscillation angle can be adjusted electronically, and this design includes a downstream feeder with dual-lane discharge. The machines were delivered to Croatia during the second fiscal quarter of 2021. Commissioning is performed and overseen by JOEST and is planned for this summer. The client ‘s demand was to provide a reliable Shakeout that could handle a large spectrum of parts whilst maintaining a small form factor due to space limitations on site. The machine should separate as much sand as possible without damaging the casts made of GERMANY. Cast-/Sand-Shakeout after green sand forming line. JOEST Shakeout with electronically adjustable oscillation parameters gray cast iron and spheroidal graphite iron.

For a longstanding client with expertise in metal processing, Dr. Goessling Maschinenfabrik GmbH designed a special conveyor plant…

For this assignment, JOEST designed a compaction table measuring 1800 x 1800, with a deck load of 12 t and an adjustable oscillation frequency of up to 33 Hz…

JOEST received an order, to build a processing plant for aluminum dross to be delivered by the end of 2019…

Cast iron parts are cooled from 550°C to 80°C on a vibrating machine. A client from Poland placed an order with JOEST to manufacture a casting cooler for cast iron sewer parts…

Blumenbecker Automatisierungstechnik develops control system for a JOEST project in a metal foundry in Mexico…

JOEST receives an order subdivided into multiple stages from a leading German automobile manufacturer…