- 09/24/2025
- Report
- Markets & Industries
Cut setup times significantly – from risky crane handling to automated die change
Die changes in megacasting typically take at least 4–6 hours, block the crane, and pose major risks to both personnel and equipment. PFEIFER automates crane handling and moves die turning to the shop floor – enabling significantly shorter setup times, greater safety, and higher productivity of the DCM.
Written by Stefan Wilde
In many foundries, die changes remain a critical bottleneck. A single change can take four to six hours, involve more than one hundred manual steps, and create numerous safety risks. The most critical issue is manual crane rigging: time-consuming, unsafe, and dependent on skilled specialists. In addition, the crane is blocked during turning operations and therefore unavailable for other essential tasks.
PFEIFER has rethought this challenge. Instead of manual crane handling, the company relies on automated rigging at the crane. This eliminates one of the most dangerous steps in the process while increasing efficiency. In addition, dies are no longer turned at the crane but floor-based – for example with the INVERTO 90 die turning device. The result: repeatable, safe processes that run significantly faster and with greater predictability.
On request, our systems can also be integrated with a warehouse management system – enabling a fully automated crane process, similar to proven solutions in the press shop.
Together with strong partners, PFEIFER also realizes complex automation projects.
The benefits are clear:
- Setup time reduction – from many hours to just a fraction.
- More safety – by eliminating manual rigging steps.
- Higher availability – measurable impact on OEE.
- Relief for personnel – less dependence on scarce specialists.
PFEIFER differentiates between greenfield and brownfield scenarios. In greenfield projects, solutions can be integrated into the plant layout from day one and operated fully automatically. In brownfield plants, retrofit concepts deliver fast results and a clear ROI – without fundamentally altering existing processes.
OEMs and Tier-1s that involve PFEIFER early in layout and process planning maximize efficiency gains and secure a sustainable competitive advantage. With lifting capacities up to 150 tons, proven references in leading megacasting foundries worldwide, and a strong partner network, PFEIFER delivers what the industry urgently needs: reliable, automated die handling.
Conclusion:
Automated die handling is the key to productive and safe casting of structural components.
Visit us at EUROGUSS Mexico or Nuremberg and let us define your benchmark in die handling together.
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