MAGALDI POWER SPA

The MCC® (Magaldi Casting Cooler) is today a well-proven technology for castings conveyance and air cooling, that combines the outstanding reliability of the Magaldi Superbelt® to an efficient cooling process.

The MCC® creates a safer work environment for operators with no exposure to noise and dust emissions, furthermore proprietary calculation methods allow to predict and guarantee the MCC® cooling performances.

The Magaldi Casting Cooler is based on the Magaldi Superbelt® “P type” technology, designed to withstand very heavy mechanical loads with material that can weigh hundreds of kilograms.
The Magaldi Superbelt® “P type” is capable of heavy bulk material conveyance, including castings, sprues and core sand.

The MCC® is equipped with a cooling tunnel, held under negative pressure, in which a stream of cooling air flows at controlled speed.

The MCC® is completed with the MISS® (Magaldi Integrated Supervision System) in order to automatically control the cooling parameters in accordance with the different types of casting to be handled. The MISS®, equipped with a dedicated PLC, receives all the status signals of the Magaldi installation and elaborates the necessary process parameters, in order to control the operation of the cooling system according to a customized logic.

Depending on the casting ID and the detected inlet temperature, the MISS® automatically adjusts the MCC® belt speed and the cooling air flow rate. Thermal simulations, performed through proprietary thermal heat exchange models and relevant calculation tools, allow the accurate prediction of the castings temperatures in order to properly moderate the cooling air flow rate, and can be used for the cooling tunnel designing.

Compared to conventional castings cooling technologies, the MCC® offers:

• high mechanical dependability (5 years warranty on the Superbelt® belt);
• flexible layout arrangement, inclined conveyance (up to 35°);
• no heavy foundations required;
• efficient air cooling;
• low power consumption, low spare parts requirements;
• fully integrated supervision system, for automatic and optimized operation;
• ability to convey fine core sand without any carry back or spillage during conveyance

In order to optimize the melting capacity and improve the operating conditions in aluminum foundries, Magaldi has developed a mechanical conveying system able to handle large amounts of aluminum scrap to load the furnace or the shredder, in a reliable way.
Usually, sharp aluminum scraps, which might also be very large and heavy (up to hundreds of kilograms), are loaded into the shredder or in the furnace via buckets, skip loading systems or conventional Apron conveyors, according to a slow and sometimes dangerous process.
To reduce the conveying time and improve the workplace safety, Magaldi customized the Superbelt^® technology: a dependable steel belt conveyor made up of partially overlapping steel pans bolted on a steel double-wire mesh, that forms a virtually sealed belt able to withstand heavy shock and impact loads.
The system’s dependability is guaranteed by the “multi-link” construction feature of the belt, a “damage-tolerant” design ensuring continuous operation without any risk of an unexpected outage.
The Superbelt^® is able to absorb heavy shock loads: the plates are made of manganese steel with a hardness of ≥400HB and a thickness of 8 + 8 mm.
In addition, the conveyor’s ability to reach steep inclinations (up to 35°) allows to reduce the plant size and easily reach the furnace/shredder loading point.

Magaldi has developed a reliable belt feeder for handling hot and abrasive materials. The working concept is similar to the one of conventional belt feeders installed under hoppers, but the use of the Magaldi Superbelt^® conveying technology ensures a higher resistance to heavy impacts and shock loads.
This equipment can be easily transformed into a weighing feeder by means of load cells. The Superbelt® conveyor is a steel belt made of partially overlapping steel pans bolted on a steel double-wire mesh, that form a virtually sealed conveyor belt.
The driving force is transmitted by friction between the head pulley and the mesh belt, while a pneumatic take-up device on the tail pulley provides a constant tension. This ensures a perfect fitting in the overlapping pans area so that fine residuals cannot leak among the pans.
The steel belt is supported by carrying idlers across its entire width in order to withstand heavy mechanical loads. Next to the loading points, the idlers can be closely spaced or mounted on a shock absorber frame.
Wear is negligible, since material is slowly conveyed with no relative motion against steel parts. Power demand for conveying and noise are at the minimum levels. The Superbelt^® can be easily converted into a weighing feeder by means of load cells, that are installed on the supporting structure of the carrying idlers, whose signal is processed by a PLC along with a dedicated software - both included in the scope of supply.
The size (length and width) of the weighing feeder depends on the layout specification and the required capacity. The actual feed rate is determined by integrating the belt speed, monitored by an encoder, and the weight signal given by the load cells.
The controller compares the actual feed rate with the desired one and it adjusts the belt speed to deliver a constant feed rate. In this configuration the Superbelt^® conveyor is mainly applied in cement factories, steel mills or wherever it is necessary to extract and dose a material.

The Magaldi Ecobelt^® is the ideal conveyor for handling hot materials, aggressive chemicals, and heavy or sharp products, ensuring a safe and environmentally friendly operation.
The Ecobelt^® key component is the Magaldi Superbelt^® designed completely enclosed in a steel casing, suitable for preventing dust dispersion to the environment. A simple mechanical self-cleaning device removes the fine residuals from the bottom of the casing.
The Magaldi O-chain^® is a chain conveyor enclosed in an independent casing, tailored around the Ecobelt^® tail section. Its function is to receive the fine residuals, removed from the Ecobelt® bottom by the self-cleaning device, and to reload them onto the Magaldi Superbelt^® .
The Magaldi Superbelt^®, the steel belt successfully used to convey difficult materials in industries where high dependability is essential, overcomes the frequent problems encountered by conventional conveyors, such as rubber belt, drag chain and steel plate conveyors. Sudden failures or the necessity for repairs of conventional conveyors can frequently lead to production losses or high O&M costs.
The Magaldi R&D dept. performs experimental tests in the Magaldi testing facility for any type of material. Custom-made technical solutions can be studied to solve specific problems for your applications.

Designed for Aluminum Recycling Plants, Magaldi has developed and manufactured a Hot Shred Conveyor System to connect the rotary de-coaters with the downstream melting furnace.
The Magaldi Ecobelt^® is the ideal conveyor to handle hot materials with aggressive chemicals, heavy or sharp products, ensuring a safe and environmentally friendly operation. The Ecobelt^® key component is the Magaldi Superbelt^®: a steel belt conveyor successfully used to handle materials under the toughest process conditions in industries where high dependability is essential.

In fact, it overcomes problems - such as sudden failures and frequent maintenance needs that lead to production losses and high O&M costs - encountered by conventional conveyors (drag chain and apron conveyors).

Furthermore, designed completely enclosed in a steel casing, the Ecobelt^® system is suitable to prevent dust dispersion to the environment and ensure the lowest temperature drop thus allowing to re-use thermal energy released from upstream processes.
Maintenance activities are very easy. All bearings are installed outside the casing, allowing trouble-free maintenance at any time and lubrication with the belt in operation.