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When Regal Cast was established, the company installed an Argon Oxygen Decarburization (AOD) vessel.

PRL, but an early decision paved the way for a strong casting operation. When Regal Cast was established,

the company installed an Argon Oxygen Decarburization (AOD) ves- sel. Te AOD refines metal, and PRL believes that Regal Cast is the smallest metalcaster in the world that has one of these vessels. Tat nugget aside, the AOD gives Regal Cast distinct advantages. Te AOD cleans and optimizes the metal, allowing larger castings to be poured. Regal Cast can melt up to 18,200 lbs. with the vessel at its largest capacity. “The largest capacity vessel we

have now is a 7-metric ton vessel. That has grown over the years. We have several 5-ton vessels also,” said Greg Raudenbush, director of tech- nical operations, Regal Cast. “The advantage of the AOD is being able to refine your material and be able to re-use your returns, clean those up, utilize those again, and to build

20 | MODERN CASTING April 2017

your bath to the size that you need in order to pour larger castings.” Recently, Regal Cast added a new

PLC server to the AOD system. What that does is help the operator of the AOD better understand how to control gases and make metal addi- tions based on chemistries after the lab analysis, and assists with controlling slag chemistries. Regal Cast’s slags are calcium oxide, aluminum oxide and magnesium oxide, which is intentional to build a slag layer over the top of the molten metal. “It just helps the operator control those things better,” Raudenbush said of the PLC.

Independent But Together Regal Cast is just one part of

what PRL does. But just because it pours metal does not mean it stays away from the rest of the business. Interactions are frequent. “We have good people. Without

them we would not be where we are today,” Raudenbush said. “Te way I look at things is I like to break a com- plex process down into simple steps, and doing those very well. Everything else takes care of itself.” Raudenbush makes it sound easy,

and maybe it is for PRL. Tat ease, however, would not be possible if not for communication. Workers from each facility meet

every week, and meetings about spe- cific customers are common. Te com- munication lines are never closed, and they run from one facility to the next. “It is complicated,” said Chris-

topher Hess, the plant manager for the LTC machine shop in Cornwall, which is steps from the corporate office. “We keep the communication lines open and bring things up as soon as we see an issue, and just to make sure everybody’s on the same page we circulate reports. Every facility does a weekly report that gets circulated

Courtesy of PRL Inc.

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