The molding line transmits data to the melt deck for automated production.
system is fed by a proprietary track- ing program. “It’s vertical instead of horizon-
tal,” said Hunter’s Dean Martin. “So, it’s about 24 ft. in diameter,” a feature that was helpful given the site’s space challenges. Te molding line communicates
the sprue location from each mold- ing machine to the melt deck. “It goes to that sprue location when the mold reaches the pouring position,” said Martin. Watts Water uses autopour tech-
nology from Inductotherm, Rancocas, N.J. in both facilities, but the new lead-free operation has an advantage in that it uses an improved method to control the pour, which enables faster production than the method used in the original facility. Te company pours a variety of
alloys, which need to be segregated. Te autopour system is designed to enable fewer workers to pour an equal or greater volume more accurately. Tey are using inert gas inoculation, and the laser-based
system monitors the pour cup and ensures the same amount is poured each time. “It is a pretty straightforward
production facility,” said Martin. “Tey operate somewhat as a job shop and change patterns several times a day during a shift.” A quick-change device for the matchplate on the flask reduces the time it takes to change a pattern, speeding production. After pouring, each mold takes a
few laps around the turntable to cool down, then proceeds onto a conveyor and goes through a series of General Kinematics, Crystal Lake, Ill., shaker pans and drums to break up and remove the sand from the outside, which is returned to the sand system. Te castings pass over a screen onto a conveyor and are tumbled and shot blast to remove the core sand. Operators separate good parts
from waste, which is remelted, and the good castings go on to grinding. Watts Water puts 100% of its product through inspection before shipment to customers.
A Bright Future “We are committed to making
this campus a success and mak- ing it as successful as it’s been for 54 years,” said Stone, who referred to the site as a phoenix rising from the ashes. Te Franklin facility first opened in 1959 and has undergone 16 separate expansions, tripling its square footage and increasing the employee count exponentially, to more than 500 today. “Tey had the vision but they also
had the courage, which is impor- tant,” said Perkul. Te next step will be to evaluate the existing met- alcasting facility and determine the upgrade options there. “We could have expanded any-
where. By expanding here, we’re recognizing the hard work, dedica- tion and excellence of our team,” said Coghlan. Te company has made the successful conversion to lead-free in the U.S. its high- est priority worldwide, for the past few years, focusing on becoming a trusted resource about the new
October 2013 MODERN CASTING | 23
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