The Wheland Foundry, in Warrenton, Georgia, poured its first gray iron in October of 1995. They are a major manufacturer of brake rotors and drums for the automotive industry. Production is between 9 and 10 million castings per year with an average casting weight of 25 lb.
The Wheland Foundry Bulk System was installed and became operational in May of 1999 by receiving two, 4,000 gallon tank wagons of phenolic urethane coldbox binder.
Binder: Phenolic urethane coldbox
Install the MT Systems' bulk resin system. The system consisted of the following:
Cost to Foundry:
Results and Benefits from Wheland Foundry Personnel
Reduced cost of resin:
The cost differential is $.035 per pound. @ 40,000 lbs per month this equates to a savings of $1,400 per month
Increased cost of shipping:
Shipping and return shipping vs. shipping and truck cleaning. $850 and $850 vs. $2500 = - $780 per month
Reduction in residual left in containers:
The residual in the tank wagon is much less than the residual in totes. Also, some totes are returned with a visible amount of resin in them that can not be removed without use of excessive labor by the supplier..
Est. residuals per month:
Given: 3,000 lbs. per tote x 0.5 % loss = 15.0 lbs. per Part I tote
Given: 3,000 lbs. per tote x 0.25% loss = 7.5 lbs. per Part II tote
15.0 lbs. x 8 totes + 7.5lbs. x 7.5 totes = 176 lbs. of resin
176 lbs. @ $1.00/lbs (est.)= $176 per month
Note: Residual was handled by supplier. In many cases, the residual must be drained and handled by the purchaser which can add a significant disposal cost.
Reduction in handling costs:
Each tote is moved 3 to 4 times before empty. The estimated labor hours to handle totes are:
Est. 2 hrs. to unload + 2 hours to load old totes x twice a month = 8 hours per month
Eliminated the need to change totes and monitor the level of the current tote:
This costs is estimated at 8 labor hours per week or 64 hours per month.
Eliminated material wasted from spills:
Estimated at 30 lbs. Part I and 30 Lbs. Part II @ $1.00 per lb. = $60.00 per month savings
Eliminated the need to clean up the spilled resin:
Elmination of labor hours and materials. Est. 3 barrels per month X 3 hours per barrel = 9 hours per month.
Reduced amount of waste disposal charges:
Before the bulk system, 36 to 48 barrels of waste per year were disposed of at $100 per barrel. After the bulk system, it is estimated 4 to 5 barrels per year will be needed for truck lines. Approximately $300 per month savings
Eliminated stock rotation and inventory labor needs:
Labor hours reduction of 4 hours per month
Eliminated the hazard of resin spills and employee exposure in totes:
Reduced danger and exposure to employees translating to goodwill and smart business savings
One employee stated, "I remember what it was like before. Now, with the bulk system in place, the operation is transparent".