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begin shifting the scale more to the efficient automated line and its market- ing energy has been directed to filling that line for the last year. Te automated nobake molding


line may not be filling as fast as floor molding, but Soucy Belgen chooses to be selective. “We go forward only with parts that


fall in the range where we are competi- tive on the market,” Villeneuve said. “If you are talking about a 100-lb. casting 20,000 times, it’s not for us—not our core business.”


In the melting area, Soucy Belgen


uses two 3-ton furnaces and two 6-ton furnaces to melt 12 tons per hour. Two separate power lines were installed so that if one goes down, another one is available. A generator can cover the gap in the connection. “With our electric substation


installed, we could eventually double our melt rate,” Villeneuve said.


Soucy Belgen produces all its


own cores and continues to also make castings on the 26 x 20-in. green sand automatic molding line and a standard flaskless nobake 52 x 60 in. molding line that existed in the original metalcasting plant. A quality department over- sees inspections. At the front end, Magma software is used to design or verify designs of almost every part. Soucy Belgen also integrated thermal analysis in their production process to assess quality of the metal to be poured. “Everything is documented and built to a standard,” said Patrick Hamel, quality assurance and engi- neering manager, Soucy Belgen. “Each time a deviation occurs, in melting, charging, or pouring, the system gives a warning and we begin trouble shoot- ing. Tis is a big improvement. We then keep the knowledge and do not


troubleshoot again and again.” As part of the Soucy Group,


Soucy Belgen keeps some capac- ity open for the sister companies, but is not captive. Every company in the group typically keeps some capacity open, but the metalcasting facility has trended more to commer- cial. With an annual production of 10,000 tons and a capacity of 50,000 tons, Soucy Belgen has a lot of room for future growth. “We offer an integrated product, we


make the casting, and can subcontract or use a sister company for machin- ing, painting and assembly. We have the ability to make measurements and inspections via CMM or 3D scan,” Villeneuve said. “We are the ultimate one-stop shop in the foundry industry and our secret has been to bring the customers here and show them our state-of-the-art facility but also meet with our team of experts.”


24 | MODERN CASTING October 2016


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