Metalcasting is a fiercely competitive industry, and maximizing productivity while maintaining and safeguarding quality is a constant challenge. Achieving that balance of productivity and product quality often requires foundries to make significant investments in new machinery, leaving the operators wondering how to meet increasing demands without exceeding budgets. Recognizing this challenge, DISA recently introduced its game-changing Speed Up Kits for the 14/19, 16/20, 20/24 and 24/28 Match machines, reasserting its commitment to product innovation and technological foresight.
The DISA Match horizontal molding technology is a green-sand matchplate process known for rigidity and precision, and capable of quick and accurate pattern changes.
The Speed Up Kit software-driven upgrade represents an ideal blend of performance enhancements and cost-efficiency. Designed to optimize cycle times using advanced algorithms, the kits increase molding speeds without compromising the integrity of the molds. This precision and reliability are exactly why DISA machines are so well known. By delivering faster throughput and operational efficiency, DISA Speed Up Kits give foundries the technological upgrade necessary to meet growing production demands while maintaining their commitment to quality products and service.
For foundries constrained by space or capital, these enhancements offer a transformational solution. Compatible with DISA Match 14/19, 16/20, and 20/24 DMM machines, the kits boost uncored molding speeds up to 210 molds per hour (mph) and cored jobs up to 160 mph. For the DISA Match 24/28 DMM, the Speed Up Kit reduces cycle times by six seconds, providing additional time for manual core setting or increasing output by up to 25% on uncored jobs.
Even foundries that do not require maximum speeds of their smaller Match machines can benefit from automatic core-setting improvements, which deliver a consistent 15 mph increase every hour—an efficiency gain that compounds significantly over time.
This is an innovation for the industry, a solution that will increase capacity without the need for expensive new installations. It redefines what’s possible for foundries, paving the way for sustainable growth and competitive advantage.
Partnership for high-speed success
Ford Meter Box, a nonferrous foundry in Wabash, IN, experienced this game-changing upgrade when it adopted the DISA Match Speed Up Kit for its 14/19 machines. The plant casts a range of brass hardware for water systems, and by pushing its mold production rates to 210 mph, it has demonstrated how innovation, collaboration, and cutting-edge technology can drive real-world results.
More than satisfied with the mold quality produced from its first DISA Match 14/19 machine, in February of 2021 Ford Meter Box readily adapted all its existing matchplates to fit the new machine, and reported a seamless integration and consistent performance. Encouraged by this success, they soon added more DISA Match 14/19 machines to the operation.
However, the foundry’s leaders saw an opportunity and proposed a bold and ambitious challenge to the DISA team: “Can we achieve even faster productivity to rival other machines on the market… but without sacrificing DISA’s quality?”
Intrigued, the DISA team accepted the challenge. With collaboration, innovation, and a shared commitment to excellence, within months the DISA programmers developed a high-speed solution for Ford Meter Box to test and evaluate.
Robust design and teamwork
The Ford Meter Box team knew that increasing machine speeds posed risks such as greater component wear. However, as Andrew Iannettoni, foundry technical manager at Ford Meter Box noted, “DISA’s robust design mitigates those risks to a negligible level. The increased mold output offsets any wear costs.” Beyond design, DISA’s willingness to listen and work collaboratively were pivotal. “Their team approach was the single largest factor in our decision to partner with DISA again.”
During rigorous onsite testing, the DISA Match machines hit a staggering 210 molds per hour. “That was the moment we knew this was the right investment,” Iannettoni recalled.
“It drives right to the bottom line, benefiting everyone,” he explained. “This focus led to a 10% productivity increase across our two Match machines—an outcome that exceeded our expectations.”
Additionally, DISA’s onsite presence ensured minimal disruption, and any challenges were addressed swiftly. “Having the people who developed the software here onsite as well as full support from the team in Denmark was invaluable.”
Ford Meter Box shared positive feedback from their scheduler, happy with the smoother workflows and faster order processing. They mentioned that since they were processing orders faster, the scheduler was able to adjust his hours to complete.
The use of the core mask on the DISA machines continues to benefit from an operator standpoint as it absorbs some of the increased speed allowing the operator to set the cores during the machine cycle time, improving the efficiency of the molding operation.
Space-saving productivity
For foundries with frequent pattern-plate changes, even for very short production runs, the message is clear: If you need increased production and your foundry processes can handle the additional volume, the DISA Speed Up Kit is a perfect solution. Moreover, it takes up no additional space, is quick to implement, and delivers immediate returns.”
While the upgrade itself is seamless, Iannettoni also noted the importance of ensuring the complementary systems can handle the increased throughput. For example, sand systems and shakeouts may need to be evaluated for throughput capacity, to avoid bottlenecks.
“Working with DISA means you have access to all the Norican brands like Simpson, Wheelabrator, and Monitizer digital solutions—you’re getting a partner that knows the ins-and-outs of your entire foundry process. We can work alongside your team to ensure maximum efficiency, helping make the Speed Upgrade Kit easy to implement and ensuring it delivers the results you need,” according to Sandy Calabrese, director of DISA Sales, North America.
Growth and market share
As a captive foundry, Iannettoni reported that Ford Meter Box’s internal customers have seen an improvement in their casting lead times because of the increased throughput. “This improvement supports our long-term goals and positions us to pursue greater market share,” he added.
The DISA Match Speed Up Kit demonstrates how collaboration, innovation, and a customer-focused approach can transform operations. By working closely with the DISA team, Ford Meter Box achieved, and even exceeded its productivity goals, and demonstrated the possibilities of new technology when it is paired with teamwork.
To elevate a foundry’s performance, the DISA Match Speed Up Kit is more than just a speed boost—it’s a strategic upgrade designed to maximize the potential of existing machinery, quickly. With proven results, robust engineering, and unmatched support, it’s a compelling option for foundries looking to enhance productivity, maintain quality, and stay competitive in the metalcasting market.