On the basis of the construction drawings , furan sand cores for manual casting are produced in our moulding shop – the polystyrene moulds required for full mould casting are produced in our joiner’s shop. These moulds, which are built precisely in the shape of the workpiece, are positioned precisely to the millimetre in the casting bed and anchored.

In the iron foundry

It’s hot in the foundry. Raw materials melt to form GG25 grey cast iron in the spark-spitting cupola furnace. High above the glowing iron mixture, the casting master – dressed in a protective suit with helmet and visor – watches to ensure the optimum filling and firing of the furnace. It’s casting day today.

The smelting point of the cast iron is reached at 1,600 degrees Celsius: now it’s tapping time. A steel drill cuts a hole through the base of the crucible and a brightly glowing jet of liquid iron spurts out into the converters. As soon as they are filled, these fireproof vessels are lifted up by a crane, put into position and tipped manually – the casting process has begun.

After 72 hours, the plate has hardened and can be lifted out of its bed – but it will still take several days until it has cooled down sufficiently for further processing.

The remaining mould sand, on the other hand, can be recycled directly in an environmentally friendly process in our modern sand refining plant and reused for the next cast plate.