CPT International 04/2016

uations requiring adaptations and corrections
to the original planning. In addition
to pure performance and price
criteria, there was also the question of
which suppliers could be sufficiently
trusted to handle even unforeseen situations
as a partner. This was one of the
decisive reasons for choosing HWS. Olsberg
had already had very good experiences
with this plant producer over decades.
Complicated construction
phase
Great attention had to be placed on the
existing space situation when planning
the molding line. Numerous modifications
to the usual arrangement of the
various plant components were necessary.
Supports, absorbers and transfer
equipment had to be adapted. In
addition, several plant sections had to
be produced as special versions. The
hall roof had to be raised to fit the enlarged
cooling plant for the cast molds.
The task of carrying out all the building
measures – including the demolition
and reconstruction of the building
under cramped conditions whilst maintaining
running operation of the foundry
– proved to be a particular challenge.
The new molding line was planned and
constructed in two stages in order to
minimize work interruptions. During
the first phase, plant components were
constructed and installed in the old pattern
construction area so that the existing
old line could continue production
during this time. In the second phase,
the old molding plant was demolished
in a few days and, following the foundation
work, the remaining part of the
new installation was quickly mounted
and commissioned together with the
completed first phase.
Building on restricted works grounds that are veritably squashed between two
hills and with structures that have grown over very many years and are closely
intermeshed with one another was a particular challenge (Photo: Olsberg)
All this required profound conversion
and expansion measures. First, a new
warehouse was built for foundry auxiliary
materials and a bypass road built
for the future hall. In order to be able
to maintain running operation, a new
piece of hall was docked at the west
end of the old hall and then building
work was carried out above the existing
hall. This was then about three meters
taller and 14 meters longer than the
former building. After that, a part of
the old hall was taken down, and the
old molding plant was dismantled and
finally replaced by the new line.
Investment in the future
“With the decision to invest this, for
us, large sum in the foundry in Olsberg
we are reconfirming our commitment
to this location and to our qualified
employees,” says Ralf Kersting. The
investment is intended to secure the
company’s existence at this site and
successfully expand it. It is often asked
whether Europe will remain a production
location in future or simply become
a pure development location for
others. The Olsberg company has undertaken
to continue being successful
in the production location of Germany
– with its excellent workforce and
technologically advanced suppliers.
With this decision, however, they are
trusting that politicians will continue
to ensure fair energy and economic
conditions in Germany. Only in this
way does a company have a chance to
remain internationally competitive.
www.wagner-sinto.de
www.olsberg.com
The new molding line
The new plant should improve, in particular, the possibilities of producing extremely demanding cast components made of cast
iron with lamellar or spheroidal graphite (GJL / GJS). Casting is carried out in bentonite-bonded molding material; the performance
is 120 complete molds per hour with a forming box size of 1025 x 775 x 300+50/300 mm. The forming sand requirement
is 99 tonnes per hour (at 120 molds per hour). There are nine core insertion spaces for open drag boxes and two for
open cope boxes. In addition to 19 manual casting spaces there are also 15 casting places available for the automatic casting
machine to be installed later; the cooling time is about 105 minutes. Pattern changes take place automatically. The drag boxes
are transported on line carriages for core insertion. The compaction of molds takes place with the help of Seiatsu.plus airflow
squeeze press-molding, whereby a specific press force of maximum 150 N/cm² can be set. The maximum bale height is
250 mm and the separation distance when lowering the pattern is 550 mm.
Casting Plant & Technology 4 / 2016 33