one is the best (without looking at the price)?’” For the team, the choice was obvious. Tey opted for the plan that provided the best production flow, although it meant more work to the building in order to gain the neces- sary space for the new equipment. “We didn’t have enough height and length,” said


Michael Whitfield, vice president of manufacturing, Lodge Manufacturing. During the expansion, a portion of the existing building


was torn down and rebuilt with higher ceilings and more floor space. Here, the company would install a DISA 250 molding machine, Simpson Technologies sand system and Inductotherm Corp. melt deck. “We basically built a foundry attached to our existing


foundry,” Lodge said. Te manufacturer kept its 290 employees in the loop on


the construction and implementation plans through state of the company addresses and weekly team meetings. “Our people were really good about explaining what we


had to do,” Whitfield said. “We were prepared.” By the end of 2013, Lodge Manufacturing had completed


the new melt center, which was sized to handle melting for all three of Lodge’s molding lines. Te melt center con- sisted of two Inductotherm Corp. 10-ton electric furnaces along with its ARMS System robot to perform melt deck operations, such as taking metal samples and checking melt temperature. Furnaces are tapped into mobile crucibles that are transported to the three molding lines via an automated overhead crane. Each molding line utilizes automated pour- ing to fill each mold. In 2014, the new molding line and sand system were up


and running. Te sand system is sized to handle all three lines, although at this point it is just serving the new molding line. Te new line makes 420 molds per hour, compared to about the same number of molds per hour on each of the older and smaller lines. However, the new line can make twice as many 12-in. skillets per mold as the older lines, meaning the line is often making four castings in a single mold. “Increasing the amount of castings in a mold may lead to


higher scrap,” Whitfield admitted, “But we are getting more saleable castings at four per mold than say, three. It’s a tradeoff.” Along with the sand, melting and molding upgrades,


Lodge Manufacturing added capacity in finishing with a new MetCast continuous shot blast cleaning machine and Didion cleaning equipment. A new wash and spray line, where raw cast iron pans and pots are guided through a thorough clean- ing process that involves stone-like scrubbing media and soap scouring the cookware clean. An additional seasoning line was also added. Te unique washing and seasoning process pro- vides Lodge’s cookware with a smooth, clean, cosmetic finish and a dark patina associated with Grandma’s heirloom skillet. The company initially hired 25 people to handle the


added production. A day after the entire expansion was complete, Lodge Manufacturing was again at 100% capacity.


Brand Recognition In 2005, Lodge Manufacturing hired a full-time public


完ћ我ҁ工项这，ѳછङ统系੧进িф生有现ثȔ Љћ我，ਈф加增要果ײȔ，પKMJU2ȕ，ױ常非ङ成 ，ङ棒最是Դ造铸望٥ћ我。级升੧进וગ有۱ثЉ得 方ઋગङգЉЗД供提ћ我է՛ҸTGIR[<求要ћ我љ۱ 一քȔ：问提并队֝ҁ工ङћ我োॐي案方把ћ我。案 ȕ;）格џਖ਼ৰЉ（ױ最案方З 择选ћѕ。ङ见易৲显是择选，પ来队֝ҁ工йث 工ך更ҟ要需वն意这管ـ，Ӧઋङई流最३流ф生д 。间空ङ需۱ӟ腾וગ新О，ҁ 副ф生՛ҸKMJU2ȕ，לЉ都چ长չچ高ङ֫现Ȕ


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ҿ熔化ਈ力ՕљґચО2UJMKҸ՛ङ 条造型ি供应金 Ֆ应达Ҹ՛ Z电炉，炉平ՖЇ配 括包心И炼熔。液ً ङ测检چ温չ样Ոײભ成完לਈ，ы֘机统系938'有 机重起式桥ङ化动ਘं，包浇ҵҖ液ً金ङ炉ӟ。ҁ工 运ӱ 条造型ি。每条造型িंਘ动浇注机完成浇注。 ङ新。੧运始开统系理ה砂չি型造ङ新，年


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З铸ў，每型 型每比ब是ѸȔ，ઈַJRKOLZON=ȕ，高 ȕ。案方ङեੱ折是这，ў铸ך更得ੂљՕў铸З 新Ձ՛ҸKMJU2，级升וગ型造、炼熔、理ה砂व随


理清՛ҸTUOJO*չוગ理清М抛续连՛ҸZYG)ZK3д增 ，ি涂֕չ洗清ङ新֨。力ਈङў铸理清д加增，וગ ૅ介涤洗状ीҵ加֨，过通پ顺ў铸坯毛ङ盆、锅铁铸 过经要还י此，洗擦ङ底彻ੴӀ炊，И池洗清ङ皂肥չ ҸKMJU2，եਫ工理הչ涤洗ङ特独。理ה烤烘չ油֕ ՛ङ炊ӀҰ滑，干Ӕ，闪व经年҅用եङ深黑Ұ泽，就 。宝؟Ѯङ母॒Ҧ


March 2016 FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION | 39


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