Ductile and Gray Iron Foundry Commited to Continuous Customer - PowerPoint PPT Presentation

Ductile and Gray Iron Foundry “ Commited to Continuous Customer Satisfaction ”

Our Company: Metalfit was established in Monterrey, Mexico in 1990 as a manufacturer of flanged pipe fittings for distribution to both the U.S. and Canadian markets. Much of the original tooling was purchased from Kuhn's, Inc. in Dayton, OH. Initially the company relied on outside foundries to supply its casting requirements. It soon became apparent however that in order to offer the high level of service Metalfit wanted to achieve we would need our own foundry. Since the principals of Metalfit all had strong foundry backgrounds it only made sense to vertically integrate into the foundry business. In 1995 we purchased a small cupola gray iron foundry in a suburb of Monterrey which is Pesqueria. The site is now approximately 9.2 Acres and has been under constant growth and development since our acquisition. We produced our first induction melt ductile iron in April of 1996. In January of 2000 Griffin Pipe Products acquired Metalfit and subsequently invested an addition $3MM in P&E over the next three years. After 3 years and several top management changes Griffin decided to discontinue it's participation in the fittings market with the exception of their large diameter proprietary fittings which Metalfit still produces today. The original owners of the company were offered the opportunity to buy the business back as Griffin realized its potential strategic value to a competitor. The company currently has approximately has 160,000 square feet under roof and 195 employees.

Markets & Products Waterworks Residential & Commercial Water

Markets & Products Agricultural Industrial

Products (Alloys & Sizes) - Gray Iron ASTM A48 – Class 20, 30 and 40 - Gray Iron ASTM A126 – Class A, B, C - Ductile Iron ASTM A536 – Grades 65-45-12, 70-50-05, 80-55-06 - Capability of Pouring: Min. 5 lbs Max. 2.5 Tons

Customers

Location: Property: 9.2 Acres Under Roof: 160,000 Sq. Feet Address: Carretera a Pesquería Km. 3, Pesquería N. L. México

Production Capabilities: - Tooling Production - Tooling Storage - Induction Melting - Green Sand Molding - No-Bake Molding - Floor Molding - Coremaking - Cleaning and Grinding - Machining (Conventional Equipment) - CNC Machining - Hydrostatic Testing - Painting and Lining

Tooling Production: Complete patternshop for the production of traditional manual pattern making, as well as with state of the art computer assisted design and tooling manufacture with CNC equipment. Materials for tooling available in wood, resin, and aluminum

Tooling Storage: In our 37,000 square feet tooling warehouse we store around 3,000 different patterns and core boxes

Induction Melting: Inductotherm Furnace Dual Track 1,250 KW Inductotherm Furnace Power Track 1,250 KW Combined Melting Capacity: 4.2 Tons/hr.

Green Sand Molding: - Semiautomated molding line flask size 30” x 30” – 12”/12” for castings from 5 to 150 pounds. - Semiautomated molding line flask size 42”x44” – 16”/16” for castings from 150 to 300 pounds.

No Bake Molding: Semiautomated flaskless molding line. Molds up to 64”x64” – 24”/24” for castings from 300 to 1,000 pounds

Floor Molding: Floor Molding Flasks up to a maximum of 110”x110” – 45”/45” for castings from 1,000 to 5,000 pounds

Coremaking: Shell and No-Bake Coremaking

Cleaning and grinding: 1 Wheelabrator Turntable Blast Machine 2 Pangborn Tumbleblast Machines

Machining (Conventional Equipment) 13 Conventional Machine Tools: 1 Horizontal Boring Mill 1 Horizontal Lathe 3 Vertical Lathes 2 Boreface Machines, 4 Multiple Spindle Drills 2 Radial Arm Drills

CNC Machining: 7 CNC Machines: 1 Horizontal Lathe 2 Vertical Turret Lathes 2 Vertical Machining Centers 2 Horizontal Machining Centers

Hydrostatic testing: Hydrostatic testing for parts that service under pressure.

Painting and Lining: Coatings and linings applied by brushing, spraying or dipping.

Quality Control: Our Quality Control System provides the framework to ensure quality throughout our process. Our laboratory is fully equipped for: - Sand testing - Chemical analysis (Spectrometer and Leco) - Mechanical testing (Universal Machine, Brinnell hardness) - Metalographic Analysis - Ultrasonic Testing - Dimensional Lay-out and Inspection We will be certified ISO-9001:2008 by the end of 2011.

Quality Control: We offer 100% traceability of our products

Storage of Finished Product: Inventory of finish ed product to provide the best possible service to our customers

List of Equipment: Qty Description TOOLING PRODUCTION 1 Quintax CNC Router 5-axis with computer assisted design capabilities. MELTING 2 Inductotherm Melting Units, 1250 Kw, with 2 Coreless Furnaces 1.5 Ton ea. GREEN SAND PREPARATION 1 Beardsley & Piper 85-B Speed-muller, 3000 Lb. batch. 1 National Engineering Mulller 2 ½ F, 2600 Lb. batch. 1 Full Installation for handling, storage and preparation of the returned sand. GREEN SAND MOLDING 1 Semi-automatic Cope and Drag Molding Line, flask size 30"X30"- 12"/12“ with International PVKL jolt-squeeze molding machines and complete mold handling system. 1 Semi-automatic Cope and Drag Molding Line, flask size 42"X44"- 16"/16“ with International PVKL jolt-squeeze molding machines and complete mold handling system. NO-BAKE SAND PREPARATION 1 Palmer Mechanical Sand Reclaimer, 10 Tons/hour 1 Gudgeon Thermal Reclaimer, 1 Ton/hour NO-BAKE MOLDING LINE 1 Palmer Continuous mixer M1000XL, 1000 pounds per min 1 Semiautomatic Molding Line with vibration table, mold handler, rollover, belt conveyor and hydraulic mold pushers. 3 5 Tons Overhead Bridge Cranes NO-BAKE FLOOR MOLDING LINE 1 Palmer Continuous mixer M1000XL, 1000 pounds per min 3 15 Ton Overhead Bridge Cranes COREMAKING 1 Shalco U-360 Shell-Core Machine, 200 pound max core 1 B&P Cormatic SF-10A Shell-Core Machine, 100 pound 1 Carver Continuous mixer, 300 pounds per min - No Bake sand 1 Dependable Continuous mixer, 500 pound per min - No Bake sand CLEANING & GRINDING 2 Pangborn 34N Rotoblast machines, 34 cubic foot capacity. 1 Wheelabrator shot blast machine. Swing Table type, 96” Table 3 Hermann Williams Bottom-up drills.

List of Equipment: Qty Description MACHINING-CONVENTIONAL EQUIPMENT 1 Union BTF 110 Horizontal Boring Mill, 5" Spindle with CNC Control 1 Bullard Cut Master M-75 Vertical Boring Mill Table 66" Swing 78" 1 Gidding & Lewis 64-VBM Vertical Boring Mill Table 62", Swing 64" 1 King Vertical Boring Mill, Table 42", Swing 46" 1 Monarch Horizontal Engine Lathe, Swing 26" 1 Natco B20B Two Way Head Borefacing machine 1 Natco B20B Three Way Head Borefacing machine 1 Natco Multiple Spindle Drill Press B3A - 12 Spindle, 1.5" Upper 2 Natco Multiple Spindle Drill Press D4B - 16 Spindle, 2" Upper 1 Natco Multiple Spindle Drill Press G4E - 36 Spindle, 1.5 Upper 1 Carlton Radial Arm Drill 15" Col, 5 Feet Arm 1 Carlton Radial Arm Drill, 9" Col, 4 Ft Arm CNC MACHINING 1 Toyoda FH-100 CNC Horizontal Machining Center 1 Mori-Seiki MH 63 CNC Horizontal Machining Center 1 Monarch VMC 45 CNC Vertical Machining Center 1 Mori-Seiki MV 65 CNC Vertical Machining Center 1 Olympia V-40 CNC Vertical Turret Lathe, Table 46", Swing 57" 1 Gidding & Lewis 60VTL CNC Vertical Turret Lathe, Table 60", Swing 70" 1 Mori-Seiki SL-7 "Slant Bed" CNC Lathe, Swing 24" PAINTING 1 Chain conveyor for dip painting. 1 Booth for spray painting. LABORATORY Complete sand control equipment: moisture teller, permeameter, sand strength 1 tester, methylene blue, grain fines rotap, shell and pep-set strength testers 1 Spectrometer Spectro-cast for 18 elements. 1 Leco Carbon Determinator 1 Ledds & Northtrup Quick-lab for carbon/silicon indicator. 1 Unitron Microscope for metalographic analysis. 2 Brinnel hardness testers. 1 Ultrasonic Tester for nodularity and wall thickness. 1 Tensile Test Machine Tinus Olsen, 30 T