When wear and tear slowed down production: How the foundry improved its circulation of black
In foundry production, operations place high demands on equipment and the right pump for foundry reduces wear, downtime and unnecessary maintenance. At the same time, reliability and availability are becoming crucial factors in keeping production running smoothly, something many maintenance managers and production engineers in the automotive industry recognize.
At one foundry, the circulation of black became a recurring challenge. Wear on the pump was increasing rapidly, causing downtime, increasing maintenance needs and driving up costs. The solution worked, but not sustainably over time.
Eventually, the problems became so extensive that they drove a change. The need for a more sustainable and maintenance-efficient solution became clear and that's when the dialog with us at Colly Flowtech took off.
The challenge: Find the right pump for foundries that can handle the wear
For the customer, the challenge was to make the pump withstand the harsh operating environment over time. This required both the right choice of materials and the right settings, which proved more difficult than expected.
The existing pump was subject to heavy wear, especially on critical components such as manifolds and diaphragms. Despite regular maintenance and replacement of spare parts, problems with unplanned stops continued.
This affected not only maintenance, but also the production rate and the working environment in the plant. At the same time, the environment set high standards. Components needed to be both innovative and easy to handle in everyday life, making the choice of the right pump for foundry extra decisive.
The customer therefore set a clear goal, to find a solution that could:
- extend the life of the pump
- reduce downtime
- increase the availability of production
- while simplifying maintenance
Solution: Right choice of material and pump to reduce wear and tear when circulating black
At Colly Flowtech, we got involved early in the dialog and went through with the customer how the pump was actually used in the process and where the wear was greatest.
Based on this, we chose to test Valor, a plastic pump from our long-term partner VersaMatic, at the most exposed position in the plant.
Previously, cast iron and metal pumps had been used in the application, but they had struggled to withstand the wear and tear over time.
The test period lasted ten months and was carried out in close collaboration with the client. Throughout the period, we monitored the results on an ongoing basis and made adjustments where necessary, to ensure that the solution worked as intended.
The entire process, from needs analysis to installation and follow-up, was handled by us at Colly Flowtech together with the customer.
Results: How the right pump for foundries improved operations
The first results show clear improvements in the plant.
The pump replacement has led to:
- reduced need for spare parts
- less and shorter downtime
- increased availability in production
- easier and more predictable maintenance
For operators, this means a safer working day, with fewer emergencies and better control of the equipment.
The follow-up work is still ongoing, but there are many indications that the solution has already had the desired effect and that there is potential to develop the work further.
Stable operation through the right choice of materials
In this type of application, where wear and tear is part of everyday life, the right choice of material can make a big difference. It's not always about more advanced technology, but about choosing something that actually works in reality.
Kent Lekeborn, who led the project, describes it this way:
“What makes the biggest difference in projects like this is when we can go from a solution that just works to one that is actually adapted to how the operation looks in reality. When we manage to reduce wear, reduce the need for maintenance and at the same time create a more stable operation, it is immediately noticeable, both in production and in the total cost over time.”
In this case, it was about just that: finding a solution that lasts better in everyday life and requires less effort over time.
Do you have a similar challenge? Maybe an application where wear and tear leads to recurring problems, high maintenance costs or unnecessary stops?
Please contact Kent Lekeborn (kent.lekeborn@colly.se) and you can talk further about what a more sustainable pumping solution could look like for you.
About Versamatic
Versamatic is an American brand of Warren Rupp, Inc. headquartered in Mansfield, Ohio, USA. The company specializes in air-operated double diaphragm pumps (AODD) and develops and manufactures pumping solutions for industrial applications with high demands on reliability and performance.
Through a global network of channel partners and distributors, Versamatic delivers its pumping solutions to industrial customers in more than 60 countries worldwide. With strong innovation, high product quality and a wide range of metallic and non-metallic AODD pumps, Versamatic has established itself as an internationally recognized player in industrial pump technology.
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