Automated High Precision Iron Foundry
inFERRO - FMS iron foundry newsflash
10/2012
Outsourcing in Ferromatrix pattern shop
Since early this year the Ferromatrix pattern division has seen a constant supply of new patterns by external pattern makers. Some of these patterns catch the eye with their size (up to 6
meters). For quite some time now our foundry has been calling in external pattern makers for
its new patterns. This is no phase-down, on the contrary.
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Outsourcing for speed & flexibility
Long before the 2009 crisis the Ferromatrix pattern
shop stopped focusing on making new patterns, a trend
persisting to this day.
“As a rule new patterns are made by third parties” tells
us Antoon Bruneel, head of the pattern division, “In our
pattern shop we focus on preventive maintenance of
existing patterns. Also when our customers opt for a
pattern revision we can execute this task in-house. In
addition, some customers send us existing patterns that
then need to be adapted internally to our own moulding
lines.”
Some of the new patterns catch the eye
with their size (up to 6 metres)
Not a surprising strategy, since outsourcing offers Ferromatrix the opportunity to work more quickly and more
flexibly. Since early 2012 Ferromatrix has received 42
new castings from several customers. “Precisely because we use external partners, we can run several projects in parallel and handle such a large amount of new
patterns” Mr Bruneel adds. “And because in this way
several projects can be handled simultaneously, we can
also respond more swiftly to new assignments.”
Standard EN 12890 – Quality Class 1
This intensive outsourcing does not compromise the quality of the patterns in any way. The requirements have been uniquely determined: all patterns and core boxes have to comply with the international
standard EN 12890 H1/M1/K1 (see table below). “At Ferromatrix we always go for quality class 1” declares the methods manager. “Strictly speaking class 2 is sufficient, but as the cope and drag boxes are
assembled automatically, we deliberately chose to raise the standard.”
Material type
Quality class
Explanation of quality class
Wood
Metal
Plastic
H1, H2, H3
M1, M2
K1, K2
1: for large quantities in hand and machine moulding shops
when very high standards are required
2: for small quantities and recurring single castings in hand
and machine moulding shops
3: for single castings in hand moulding shops
Automated High Precision Iron Foundry
In-house pattern makers focus on
preventive maintenance, pattern
revisions and adapting existing
patterns to our moulding lines.
The 1016 active patterns are neatly
stored in a covered warehouse provided with sprinklers for fire protection.
Since the cope and drag boxes are
assembled automatically, Ferromatrix applies stricter standards than
required for its patterns..
New sand mixer for hand moulding line
The existing hand moulding line received a facelift and was converted to produce long castings. Today specific components for the
textile weaving machines of the affiliated company Van de Wiele
are being made with it. At a later stage also external customers
will be contacted.
During the summer holidays a new sand mixer was installed at this
moulding line. The sand mixer has a capacity of 60 tons/hour. Original plans to invest in a semi-automated line have been dismissed
for lack of cost-effectiveness. In any case the order book for this
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line is already well filled. For 2013 we foresee to cast 1.500 tons.
Evaluation of one year of solar panels
Besides the 1.248 solar panels at Ferromatrix, on the entire premises of
the Van de Wiele Group in Kortrijk (Marke) 3.222 solar panels were installed. Those were mainly put into service in the course of 2011 (the last
ones in august). The energy produced in one year amounted to 87.419
KWh for Ferromatrix and 218.035 KWh for the entire site. Taking into
account an average yearly household consumption of about 3.500 KWh
Ferromatrix supplies the equivalent for 25 households and the whole
group for 62 households.
A beloved colleague passed away
On June 30th Ferromatrix bid farewell to Dirk Vanneste, head of the fettling department.
After courageously fighting his illness, he passed away peacefully surrounded by the love of
his wife and three children. In his spare time Dirk (° 18/03/1965) was trainer of the local soccer club K.D.N.S. Heule. ‘I want to sleep, I want to rest’ were his last words. May you rest in
peace, Dirk.
Ferromatrix
is a high precision cast iron foundry for large and medium size castings moulded on
automated furan sand moulding lines.
Grey iron • Ductile iron • Vermicular iron • ADI cast iron • Special alloyed cast iron
• 2 Ton Moulding line - Flasks: min 1000 x 1100 mm - max 2000 x 2500 mm (5 sizes)
• 5 Ton Moulding line - Flasks: min 2500 x 2500 mm - max 3000 x 4000 mm (5 sizes)
Ferromatrix nv - Michel Vandewielestraat 7 - B-8510 Kortrijk (Marke) - Belgium
Tel +32(0)56/24 33 31 - [email protected] - www.ferromatrix.com - BTW BE 0432 779 356 - RPR Kortrijk