Johnstown Corporation (Formerly USX) has been in operation for 99 years. They specialize in medium to large steel castings and rolling mill rolls. Production capacity at this facility is roughly 25,000 tons per year utilizing Alkyd Oil, Phenolic Urethane No-Bake and Clay Bonded core and mold technologies.
General Foundry Information
Casting Metal Type:
The objective of the project was to reduce binder consumption and improve process repeatability. Additionally, high / low binder recipe capabilities and reduced mechanical problems were needed.
They installed the MT Systems SMART PUMP Control System on three of their continuous mixers. This was done in three stages with a design to give them the consistent repeatable chemical addition along with greatly improved mechanical reliability.
To accomplish this, each mixer was outfitted with the following hardware:
The system fully compensates for line restrictions, chemical viscosity changes, pump wear, and operating pressure changes. If for any reason the chemical levels can not reach their set point and SMART PUMP is unable to compensate, the system alarms to notify the operator or shuts down.
Results and Benefits:
Monetary Savings/Pay Back:
The original projected time was 14 months and the actual pay back was 9 months.