Types and grades of the cast iron produced:

Material:

• grey cast iron according to PN-En 1561 until 30,000 kg
  • EN-GJL-100
  • EN-GJL-150
  • EN-GJL-200
  • EN-GJL-250
  • EN-GJL-300

• Nodular cast iron according to PN-En 1563 until 13,000 kg
  • EN-GJS-400-18-LT (notched -bar value in low temperature)
  • EN-GJS-400-18-RT (notched-bar value in ambient temperature)
  • EN-GJS-400-18
  • EN-GJS-400-15
  • EN-GJS-500-7
  • EN-GJS-600-3
  • EN-GJS-700-2

Once a new modern induction furnace with capacity of 12 tons is purchased , the Company will be able to produce the nodular cast iron castings until 20,000 kg of weight.

Technology preparation:

During the process of technology designing, constructing and preparation, the Foundry takes advantage of CAD computerised production supporting systems ( Solid Edge).

In the event of new casting production initiation, we carry out the verification of entire founding technology based on the computer simulation outcomes for cast iron castings pouring and solidification.

Applied software shortens designing process as well as the time devoted to production preparation.

Technological Department of "ELZAMECH" Foundry secures the full range of designing services.

Pattern execution:

Wooden and laminated tooling is outsourced to pattern-making companies. Our own patterns as well as the patterns supplied
by the customers are stored in the warehouse.

Metal melting:

The following cast iron types are melted by "ELZAMECH" Foundry:

• grey cast iron according to PN-En 1561 until 30,000 kg
  • EN-GJL-100
  • EN-GJL-150
  • EN-GJL-200
  • EN-GJL-250
  • EN-GJL-300

• Nodular cast iron according to PN-En 1563 until 13,000 kg
  • EN-GJS-400-18-LT (notched -bar value in low temperature)
  • EN-GJS-400-18-RT (notched-bar value in ambient temperature)
  • EN-GJS-400-18
  • EN-GJS-400-15
  • EN-GJS-500-7
  • EN-GJS-600-3
  • EN-GJS-700-2

• alloy cast iron

Grey cast iron is melted in a cupola while nodular cast iron in two inductive furnaces PIT 6000 (capacity 6 Mg and efficiency 18 Mg / day)
and PIT 5000 ( capacity 5 Mg and efficiency 10 Mg / day).

The Foundry has already initiated the investment comprising the purchasing of a modern crucible furnace ( capacity of 12 Mg and efficiency 9,270 kg / h). This will enable us to produce the nodular cast iron castings with 20 Mg of weight.

For the time being we remain the sole manufacturer of big castings intended for wind generators in Poland. Consequently to high worldwide demand for the nodular cast iron castings for wind generators and power turbines, the investment in the new furnace will give us a chance for intensive growth in the years to come.

Moulding:

Moulds are made by hand. Our foundry uses organic sands (furan resins). Moulding sandmix is prepared at IMF sand-mill with efficiency
of 50 t/ h.

During the moulding process facing sand is applied (fresh sand applied directly at a pattern) together with backing sand ( sand originating from reclaim used to fill in a mould).

Mould shaking out:

In order to perform the mould shaking out, the Foundry uses a knockout grid with dustproof and noise absorbing casing. The entire volume of the sand knocked out is transferred to an automatic sand reclamation line with efficiency of 12 t/h.

Casting fettling:

Once knocked out, the castings are passed to a fettling shop, where they are cleaned off from sand remains and other imperfections on their surfaces.

Heating treatment and machining:

Heating treatment is executed in two furnaces:

• gas-fired one with the working chamber dimensions of 3000 x 5500 x 2000 mm,
• electric one with the working chamber dimensions of 2800 x 1700 x 1000 mm.

In order to provide the complete services for our customers "ELZAMECH" Foundry offers castings with maximum processing - a fully finished product to be delivered to a customer's assembly line. Hence our offer is completed with machining treatment which is outsourced to our sub-suppliers as well as providing own machining service in our modern and newly opened Machining Centre (DMC 200 FD made by DECKEL MAHO Company).

Depending on the customer demand we offer:

• rough machining,
• finishing.

Casting painting and packaging:

In line with a customer's demand we deliver the following castings:

• rough castings with corrosive protection
• primed castings
• coated with paints in verified colours
• galvanised castings

Packaging in line with customer requirements.