First Japanese Foundry Orders SinterCast Package

Toa Koki Ltd. will develop, produce diesel cylinders, other large engine parts

Toa Koki Co. Ltd. will be the first Japanese foundry to install SinterCast Ltd.’s process control technology for compacted graphite iron production, following an order for the developer’s Mini-System 3000. Toa Koki is a manufacturer of diesel engine parts for industrial machinery and marine vessels, and plans to use the SinterCast system for series production and product development.

SinterCast developed and supplies process control technology for producing CGI, and its systems are in use by automakers and their suppliers, and industrial engine manufacturers worldwide. It indicates the process is being used for series production of over 46 CGI components ranging in size from 2 kg to 17 metric tons.

System 3000 is the third generation of the SinterCast technology and includes hardware and software in modular package that monitors CGI production in real-time. The Mini-System 3000 is a scaled-down version used for CGI product development, prototyping, and niche-volume production.

Toa Koki operates three foundries producing cast iron cylinder liners, cylinder heads, cylinder covers, pistons, and turbocharger housings for marine and stationary diesel engine. It supplies many large industrial groups, including Mitsubishi Heavy Industries, Kawasaki Heavy Industries, Mitsui Engineering & Shipbuilding, Hitachi Zosen Diesel & Engineering, and Makita Corp. Also, about 45% of its output is exported, including to manufacturers like MAN Diesel, Doosan Engine, STX Engine, and others.

According to SinterCast, The Toa Koki installation is set to take place early in December and follows more than two years of on-site trials. Toa Koki will have independent CGI product development capability, and may result in production of more than 100,000 engine equivalents per year in the near-term.

The developer also noted that this installation brings the possibility for it to raise its involvement in series production of components other than automotive cylinder blocks and heads. Presently, those products represent about 15% of SinterCast’s series production volume.

"The installation commitment from Toa Koki results in five new installations during 2011, fulfilling the installation target initially presented during November 2010. We are experiencing a clear increase in CGI product development and installation planning and we anticipate additional installation commitments over the next six months," stated SinterCast president and CEO Dr. Steve Dawson.

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