Image 4: ECOCURE SL meets the highest requirements to deliver superior quality of appearance anddimensional accuracy.

Fig. 1

MOULD AND CORE MAKING

Fig. 4

Fig. 2
Fig. 5
Fig. 3Fig. 7

Image 3: As part of the leak test, the cast parts are tested for possible gas defects and porosities caused by
Image 6:
quantity of part 2 that needs to be added can be reduced by more than 20 % with the newshrinkage. In the area of boiler production in particular, the rejection rate due to gas defects was reducedbyThemore
ECOCURE SL system. Dosing quantities of the rival product: 0.52 % of part 1 and 0.52 % of part 2; dosing
than 5 % with ECOCURE SL.
quantities of the ECOCURE SL system: 0.53 % of part 1 and 0.40 % of part 2.

Fig.2 (opposite page) As partof the leak test, the cast parts
are tested for possible gas
defects and porosities caused byshrinkage. In the area of boiler
production in particular, therejection rate due to gas defects
was reduced by more than 5 percent with ECOCURE SL
Fig.5 (left) The quantity of part2 that needs to be added canbe reduced by more than 20 per
cent with the new system. Dosing
quantities of the rival product:
0.52 per cent of part 1 and
0.52 per cent of part 2; dosing
quantities of the new system:
0.53 per cent of part 1 and
0.40 per cent of part 2

Image 5: John Huskes, Senior Production Engineer at MGG, is delighted about the excellent quality of t
This means a reduced build-up of deposits and therefore
produced cores.
less need for tool cleaning.
By using the new generation of binders, MGG
ultimately achieved a significant reduction of emissions
during the casting, cooling and shake-out processes, while
maintaining excellent dimensional accuracy at the sametime.
Fig. 6
As revealed by the example formulation (fig.5), thedosing ratio is more favourable with the new technology
Image
8: MGG
alsoofuses
a low-pressure
can be used to cast particularly thin-walled
Image 2: Inside MGG’s core shop in Tegelen.
Image 4: ECOCURE SL meets the highest requirements to deliver
superior
quality
appearance
and sandcasting process
than with the rival product; in addition, the amine content
Imagethat
7: Generationof visible smoke is a thing of the past in the Dutch foundry.
parts.
for component 2 contains a special
dimensional accuracy.
IMPRESSIVE CO-OPERATION
is a convincing 30 per cent lower as compared to thepolyisocyanate component. SpecialRESULTS
competitive product. While the available processing time isAndrea Ferkinghoff, ProTEC Marketing, and Verena Skelnik, ASK Chemicals,
are therefore high. “We are looking
additives that interact exactly
A conventional cold box system canup to 90 minutes long with the ECOCURE SL technology,
consider the importance of added supplier value in the foundry industry
for partners who will not only sell uswith the adapted component 1
be described as a three-part system:
MGG had a time window of just 60 minutes when using
their product, but who will provide
were added. With this uniquecomponent 1 is comprised of aroundthe rival product. The advantage the new technology
The value chain in industrial production is complex
QUALITY ASSURANCE ON ALL
comprehensive support and input forcombination, the total amount of
55 per cent phenolic resin andbrings to the Dutch foundry is therefore clear - increasedand requires all those involved to work with the utmost
PRODUCTION LEVELS
further development in production,”binding agents can be reduced by
45 per cent solvents. Component 2 isproductivity.
efficiency in production and quality assurance. The
MGG produces successfully castsaid Huskes. “The decision20 per cent. The new SL technology
mainly comprised of polyisocyanate
In addition, MGG discovered that the sand used by theincreasing requirements are driven by the ever moreparts that are close to the limits ofmaking processes for selecting
contains VOC-free solvents thatderivatives and 15 to 30 per centcompany reduces the absorption of moisture by 60 perwhat is physically possible. The
stringent standards for reducing emissions and optimising
suppliers are highly complex. Couse high-quality chemicals. In thesolvents. Finally, the tertiarycent. The rejection rate of the produced sand cores isfoundry meets the ever increasing
operation, technological expertise
quality management (ISO-TS 16949). This also affects theformulations, the known plant esters
amine catalyst, which initiates thecurrently at 2 per cent. Especially in boiler production,requirements through intensive
and economic efficiency play anfoundries and their suppliers. Manufacturers are expecting
are replacedthese solvents
reaction, forms component 3. BothImage
6: Thebyquantityof partto2offerthat needs
tofoundries
be addedcanreduced high-quality
by more than
20 the% with the new
where
rely
onbe
particularly
cores,
information sharing with customers
important role here.”
their suppliers to get involved in the development andusers the unique
option ofreducing
acomponent 1 and component 2 ofECOCURE
SL system.
Dosingquantitiesof therate
rival
product:
0.52% ofwaspartreduced
1 and by
0.52
% of part 2; dos
rejection
causedby gasdefectsmoreand suppliers and by continuously
part of theofemissions.
production tasks on an increasingly comprehensive level
the ECOCURE SL system:than0.53% ofpart 1 and 0.40 % of part 2.
the binding agent can contain special quantities
5 percent.
optimising the production of cast
DRIVING SUCCESS WITH
and to provide evidence of sustainable production because
The physical properties of theadditives that are used to optimiseparts. In this respect, it can draw
INNOVATIONS
the pressure is growing to produce in an energy-efficientcores that were produced using
special features or casting properties.
SUSTAINABILITY CRITERIA SUCH AS ENERGY AND
upon a solid portfolio of support
MGG has always used highthe new technology were able
and material-efficient way.
The polyurethane reaction consists
RESOURCE EFFICIENCY - A COMPETITIVE FACTOR
Image 3: As part of the leak test, the cast parts are tested for possible gas defects
and asporosities
causedbytools such
simulation
methods,
performancefrom quality
renowned
to convince MGG. Huskes wasof phenolic hydroxyl groups inchallenges
faced every
day at Image
the5: John rate
Huskes,SeniorProduction
Engineerat MGG,
is delighted
about binders
the excellentof theEnvironmental friendliness and sustainability play anshrinkage. InThesethe areaof boilerare
production
in particular,
theMGG
rejection
dueprototype
togas defects
wasreducedby
more
production or rapid
suppliers. Conventional or standard
impressed by the dimensional
component 1, which react with thecores.
than 5 % Netherlands
with ECOCURE
BV SL.
foundry (hereafter MGG)produced
in Tegelen
important part today when it comes to selecting suppliers
prototyping. MGG does not see
cold box binders have neveraccuracy and thermal load capacity
NCO groups (isocyanate groups) in(Netherlands) near the German border. With an annualand foundry aids.
itself as a developer, but rather assatisfied the Dutch company’sof the cores that were shot in Tegelen
component 2. In the new solventproduction of more than 12,000 metric tons of cast
For this reason, MGG commissioned the IFG (Instituta process optimiser which works
high requirements. In 2011, MGG(figs.3 and 4).
less system, component 2 has beenaluminium, the company operates one of the largest
für Gießereitechnik) in Dusseldorf to examine the BTX
closely with its customers. The aim isbegan testing the new ECOCURE
The good core removal capability
specifically designed to be just as
aluminium sand casting foundries in Western Europe. Highemissions and odour produced by the ECOCURE SL
to produce ‘ready-to-install’ products
solvent-less binder technology (SLis a result of using less organic
effective as a normal 2-component
system and by its rival products used to date. Here, too,quality series production cast parts for customers from allthat meet the customers’ hightechnology). Always pursuing thematerial while maintaining the samesystem, but without using solvents.
the new development from ASK Chemicals displayed its
over the world are produced by more than 400 employees
requirements. According to Johnaim of reducing BTX and odour
amount of oxygen during casting.
The solvent-free formulation
strengths. While the odour generated was 20 per cent lower
on an area of 29,000m2. The commercial vehicle, passenger
Huskes, senior production engineer
emissions, improving the physical(fig.6), the BTX emissions were reduced by 60 per centcar and boiler industries in particular rely on cast parts
at MGG, the only way to do this is
and thermal properties of the cores(as compared to the other two cold box binders) with theby implementing stringent quality
produced in the Netherlands. A production output of thisand ultimately, reducing the use of
new technology. In addition, visible smoke development
MGG
assurance (fig.2).
Netherlands is basemagnitude requires strategic partnerships with suppliers,
binders and amines with this new
d in Tegelen and isinn
is a thing of the past in this foundry. For the foundryovatoniveeofalu
theminium sand casting
whose products must satisfy the highest requirements in
These same requirements aretechnology. After an approximate
foundries in Wester most modern andIn addition to the es
and not least for its employees and the people livingnEu
also passed on accordingly to theroterms of reliability.
peone-year testing phase, seriesalso uses low pressur tablished aluminium sand casting proc .
nearby in Tegelen, results like these are an important andsuppliers of foundry aids such asese
In the process, foundry chemicals such as coatings andproduction finally started with thedeveloped for contr sand casting (fig.7), a patented syste s, MGG
clear signal that the company is doing its best to support
mollbinders
andcoatings.
new generation of ECOCURE
binders for the casting process may seem insignificant at
mechanical proper ed casting. Very thin-walled castings speciallyenvironmentally-friendly technologies.
tiewis,thwhNeedless
tosay,
theeverrisingimich
prsolvent-lessbinder
technology
fromovarfirst glance. But far from it - they play a crucial role in theede mainly used in copassenger cars mammThis best practice example highlights the importance ofer
ciadelve
hicles andcompetitive pressure results from theASK Chemicals. While MGG
production process.
with this process (LP by renowned manufacturers, can be
the contribution made by suppliers of foundry consumablesmaSC
Image 6: The quantity efficiencyof part 2 thatneeds
to be added
can be reduced
bymorethan20%withthenewnu/lofaw
ctu
prdrivetoproducecastings
reesd
relied on two suppliers of cold-box
sure sand casting).
This is why the Dutch core-moulding plant(fig.1),
quality mponents
Ththate prcan
ECOCURE SL system.inDosing
quantitiesof theproduct: 0.52 % of part 1 and 0.52 % of part 2; dosing
to foundries’
added value. The use of efficient, lowoducbe
for the boile
tiousedImage 8: MGG alsocouses
a low-pressure
sandcasting
to hcast particularly
thin-walled
n of higless andless time,withrivala smallerr industry is processbinders in the past, the company has
The company relie
which produces 15,000-20,000 shots per weekand uses
anotherquantitiesof the ECOCURE SL system: 0.53 % of part 1 and 0.40 % of part 2.
importaemission
bindersystems in particular shows that the basis
ntsparts.
onfietheld.
expertise of its emplo
amount of effort and more complex
demonstrated its near one hundred
built-up and passe
400 metric tons of sand, has been working closely together
yees that has beend on in Tegelen forfor quality improvements and emissions reductions cangeometries,
while
keeping
process
percent
commitment
tothenewma
as a pioneer in theny years now. MG
with ASK Chemicals, one of the leading foundry suppliers,
Gareas of engineerin
already be created at the component production stage by
reliability at a consistently high level
g and development, sees itself
efficient, resource-saving technology
closely together wi
for years and uses the company’s high-quality cold box
th its customers. Thand works
carefully selecting the components and consumables for thee- or improving it - at the same time.
supply chain ranges
assembly-ready prever since the successful completionoducts. www.ask-chbinders.
from casting torelevant casting process.
emicals.com
The expectations placed on suppliersof the testing phase.

Strong INNOVATION PROCESSES in Foundries

About MGG Netherlands BV

94

FOUNDRY TRADE JOURNAL April 2014

FOUNDRY TRADE JOURNAL April 201495