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PRODUCTION TECHNOLOGY

QUALITY | MODERNITY | THE RIGHT PEOPLE

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FANSULD TECHNOLOGY

QUALITY

The “FANSULD” Iron Foundry is a dynamically growing Polish family businessfounded in 1991. The company’s over 25 years of experience has allowed it tobuild a strong and well-established brand on the market. FANSULD is a leadingPolish producer of cast iron, enjoying the reputation of a modern and reliablecompany continually investing in innovative process and product solutions.The full portfolio of products is made at the plant in Końskie (the ŚwiętokrzyskieProvince). The company exports products i.a. to the markets of: Germany, theNetherlands, France, Austria, Romania, Czech Republic, Slovakia and Croatia.

Since the inception of our foundry, we have put tremendous emphasis on

continual technological development which resulted in achieving a high quality

of the products we offer. This fact has been confirmed by numerous awards i.a.

by the Certificate of Innovation - the Fansuld Iron Foundry is among the 500

most innovative companies in Poland according to the PAN Institute of Economic

Sciences.

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As of 2006, the company has a certified quality management system inaccordance with ISO 9001.Implemented in 2011 was an environmental management system in accordancewith ISO 14001.In 2016 was implemented BS OHSAS 18001.The Certificates of Compliance were issued by the TÜV SÜD MANAGEMENT SERVICE Company.

March 2012 saw the end of works associated with the launching of the project– the new, innovative process line. All the machinery comprising the new,automated moulding line was produced by the world’s best companies which have been making foundry equipment for decades:• flaskless FBO V moulding machine - HWS (Heinrich Wagner Sinto) - Japan• turbine mixer - EIRICH - Germany• vibrofluidized cooler and shake out machine - KÜTTNER - Germany• automated induction pouring furnace - OTTO JUNKER - Germany• dedusting system - Nederman (formerly Dantherm Filtration) - Sweden• core shutters - PRIMAFOND - Italy

It is worth mentioning that theFBO V moulding machine is the firstdevice of its kind and this size installed in Europe.Thanks to the technologicaladvancement, the new process lineopens up a wide range of productioncapabilities.

The automated form pouring machine is equipped with a feeder of the innoculantwhich allows to carry out the iron innoculation process using the metal streamapplication technology. Operation of the feeder is controlled in a fully automatedsystem both in terms of the innoculant quantity and the time and intensity of itsfeeding. It ought to be noted that this innoculation method used by most moderniron foundries is the most effective one from the standpoint of the impact on thestructure and properties of cast iron.

Installed in 2012 was the induction pouring furnace by OTTO-JUNKER RGD Ge4/250 with the automated form pouring process and the iron heating and holdingfunction. One of the innovative features of the “intelligent” pouring system isits ability to repeat (memorize and imitate) the dynamics of pouring of individualforms within the batch pouring process.

We specialize in the production of gray cast iron castings:• EN-GJL-200 in acc. with PN-EN 1561 ( GG 20 in acc. with DIN 1691)• EN-GJL-250 in acc. with PN-EN 1561 ( GG 25 in acc. with DIN 1691)• EN-GJL-300 in acc. with PN-EN 1561 ( GG 15 in acc. with DIN 1691)

We provide comprehensive machining of castings on CNC machining centersalong with the execution of measurements on measuring devices.

MODERNITY

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FANSULD TECHNOLOGY

1. SAND PREPARATION STATION

The moulding masses are executed on an automated Sand Preperation Station with the capacity of 80 Mg/h based on devices by Eirich-Küttner.

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MOULDING MACHINEMACHINE

TYPEMOULD

SIZE[mm]

PRODUCTIONVOLUME

CASTING WEIGHT[kg]

flaskless automatedmoulding machine withhorizontal divited line an efficiency of 90 moulds/h

813x

813x

350/350

medium andlarge batches up to 100

hws FBO-V

2. MOULDING

3. PRODUCTION OF CORES

MODERNITY

In our internal Core Shop we using two technologies:• Cold Box - cores up to 30kg• Hot Box - cores up to 0,5kg

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4. MELTING AND POURING OF METAL

The iron melting process is carried out in hot-blastcupolas. The cupolas are equipped with a direct oxygeninjection installation by Air Products and an exhaust gasdry dedusting installation with an efficiency of 99.7%.The pouring is executed using the OTTO-JUNKER RGDGe4/250 induction pouring furnace.

5. SHOT BLASTING

The shot blasting of castings is performed in 2 shot blasting machines made by the AGTOS company

MR - 750Shot-blasting stream chargingbox cleaning machine

HT - 13Shot-blasting streamsuspension, cleaning machine

MODERNITY

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FANSULD TECHNOLOGY

MODERNITY

6. PAINTING OF CASTINGS

POWDER COATING

DIPPING LINE

Our internal painting shop is using 3 technologies:• powder paint• painting by dipping (only water base paint)• paintig by spraing (only water base paint)

7. CNC MACHINING

The CNC machining process is performed on MAZAK (HCN-6800)

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8. MEASUREMENT

The process of quality control and product measurement is performed inter alia on Mitutoyo Renishaw

MODERNITY

9. PACKAGING

Packaging according to customer requirements e.g. film-wrapped castings onpallets, in wooden boxes, on EUR and UIC pallets etc.

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FANSULD TECHNOLOGY

Environmental protection constitutes an integral part of the legal system andhas a greater and greater impact on your lives. Care of the natural environment is a moral responsibilities towards the future generations.The company’s concern for the natural environment is documented by the implementation of the environmental management system in accordance withPN-EN ISO 14001:2005, confirmed by the ISO 14001 certificate.Awareness of both the Board and the staff, supervision and monitoring of theimpact on the environment and the pursued environmental objectives all guarantee that the company’s development is done with respect for the natural environment.

The company undertakes to comply with the legal and other requirements regarding environmental protection, associated with the conducted business activity at all stages of product creation by means of:• reduction of atmospheric emissions from

technological processes• rational waste and sewage management• reduction of noise emissions to the

environment• reduction of the amount of waste• rational energy and raw materials

management• water use optimizationTECHNOLOGY

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Thanks to the use of CAD engineering software, we are able to quickly develop the product shape, process technology and determine the cost of implementation. 3D designing allows precise development of documentation and execution of foundry equipment with the use of CNC technology.

We provide comprehensive design and executive services:• DESIGN

preparation of the foundry equipment (patterns, core boxes etc.) and casting design based on the provided documentation or detail

• TOOLING

- execution of complete tooling (patterns, core boxes etc.)

- adaptation, optimization of the existing tooling,

- equipment repair and regeneration

In order to ensure the highest quality and reliability of our products, we constantly monitor the technical parameters of theprocess. Our laboratory routinely carries out a number of tests associated with metallurgy and the form creation technology.With a complex production process like the one we deal with, even the tiniest details are of great importance.

THE RIGHT PEOPLE