According to the World Foundrymen Organization WFO, Turkey is expected to become Europe's second largest producer of castings within a few years, taking its place behind Germany which is in top spot. The Turkish foundry industry has become a dependable source of supply to European and American industry, particularly for vehicle makers.The turned parts, forgings and castings must meet stringent quality standards. This also applies to the Ekdöksan foundry which recently installed a new molding line including EIRICH sand preparation equipment to expand its production capability.
Production of high quality products at low, competitive prices was the main reason why the family-managed company Büyük Eker Bijon decided to invest in the expansion programme at the Ekdöksan foundry. Brake drums, brake discs, wheel hubs and flywheels for commercial vehicles are produced on the new line which went into operation at the end of 2013. These products are supplied to the domestic and export markets.
Preparation of the bentonite-bonded foundry sand has a major impact on production quality. EIRICH has been a technology leader in this application space for many years, and that is the reason why the customer chose EIRICH. The EIRICH mixing system guarantees outstanding, reproducible molding material quality. All of the constituents are perfectly homogenised, and the dosed water is completely and uniformly distributed. These performance factors together with the intensive wet mixing phase ensure optimal bentonite activation and complete coating of the sand grains, resulting in the production of perfect castings.
EIRICH delivered an R28-41 mixer to Ekdöksan. The machine has a batch capacity of 4 000 litres and a finished molding sand throughput rate of 104 m3/h (approx 90 t/h). The control system and a full set of dosing and weighing equipment with table feeder to discharge the prepared foundry sand was included in the delivery.
A QualiMaster AT1 online testing unit, which automatically extracts samples from each molding sand mixture to check the compactability and sheer strength, is embedded into the production inspection and control system. The results are transmitted to the control system and are used for automatic correction of additive and water feed. This guarantees high reproducibility of the specified molding material parameters.
EIRICH has supplied a number of foundry sand preparation systems to Turkey in recent years. Besides improved casting quality, high system availability due in large part to relatively low wear on the mixing tools is a crucial factor for customers.
Contact: Gerald Feuerstein, E-mail: firstname.lastname@example.org