Challenges in the Foundry
Foundries today face major challenges: rising costs, stricter environmental regulations, and the demand to deliver the highest quality at the same time. Especially in mold treatment, conventional methods are reaching their limits. Inaccurate spraying processes lead to high consumption of release agents, which not only drives up costs but also causes emissions in the production hall. These emissions burden the working environment and increase the effort required for cleaning and disposal. At the same time, the cooling effect of conventional spraying shortens mold service life and results in more frequent maintenance intervals. Added to this are long cycle times, which restrict productivity and increase unit costs.
Our Solution: Micro-Spraying and Minimum Quantity Lubrication
With our innovative spraying technology for hot- and cold-chamber die casting machines, we rely on micro-spraying or minimum quantity lubrication (MQL) with release agents. This means: minimal use, maximum effect. The precise and reproducible spray pattern produces surfaces of consistent quality – even over long production runs. Even after machine downtime, such as over the weekend, the nozzles remain free of blockages or drying. This ensures trouble-free processes and high reliability.
Efficiency & Cost savings up to 70%
Our spray modules offer numerous benefits that directly impact production efficiency and quality:
- Cost reduction through material savings of up to 70%
- Needle-closing coaxial spray heads with flexible attachments (round spray, flat spray, swiveling)
- No sticking after machine downtime due to the self-cleaning effect of the spray heads
- Independently adjustable spray air and medium quantity per spray head, reproducible and precise
- Fine atomization with large surface area for optimal wetting and excellent surface quality
- Separate control of blow-out air for maximum flexibility
- Shorter travel paths due to the blow-out bar positioned below the spray tool
- Reduced cycle times, as blow-out is often unnecessary or does not need to be repeated
Sustainability and Reliability for Foundries
The advantages of our technology go far beyond the technical aspects. They create tangible added value for foundries:
- Economic: Less material consumption, lower cleaning costs, and reduced disposal costs.
- Ecological: Fewer emissions in the production hall, efficient use of resources, and a contribution to greater sustainability.
- Quality: Consistent surface quality over long production runs.
- Process reliability: No disruptions from clogged or dried-out nozzles, even after downtime.
- Productivity: Shorter cycle times and higher output per shift.
A Success Story – A Case from Practice
A customer with a hot-chamber die casting machine had a standard spray system with a spray pattern that was not fine enough and often caused the release agent to dry out over the weekend.
Customer requirements:
- A refined spray pattern that remains unchanged, precise, and consistent even after months, positively affecting the surface of the components.
- A release agent for fine application that also serves to blow out/clean the mold.
- A spray system that protects the die casting mold from adhesion of zinc, magnesium, or aluminum, with a comparatively small spray head that can spray in all directions.
Our solution: We replaced the existing system with our INDUTEC® MS Spray Module 10-fold. With the precise flat spray attachment, we achieved a significantly finer, consistent spray pattern. Thanks to the needle-closing coaxial spray heads with self-cleaning effect, dried-out nozzles are a thing of the past.
The result:
- A fine, reproducible spray pattern with consistently high surface quality.
- No more blockages after downtime – trouble-free processes even after weekends.
- Higher process reliability and reduced maintenance effort.
The INDUTEC® MS Spray Module is available in standard 6- and 10-fold versions. In the micro version: 4- fold, 6-fold, 8-fold, and 10-fold. In our customer example, a flat spray attachment was used.
Optionally, round spray, ring spray, or swivel spray attachments are also available. The spray module blows out/cleans and wets the surface completely, produces the desired finer spray pattern, and drying of the release agent is no longer an issue.
Problem solved, customer satisfied!
