The G&W Electric / Manufacturer’s Brass and Aluminum Foundry in Bolingbrook, IL, has been operating for more than 70 years, but its 2023 investment in a new flaskless molding machine and mold handling line, with intelligent process control, is bringing significant improvements to the operation. The Sinto FBO-III 20x24 machine integrated with the Industry 4.0-capable Sinto Smart Foundry platform is allowing the metalcasting operation to enhance its production processes while improving plant safety and efficiency, and improving finished product quality.
Since 1905, G&W Electric has been manufacturing components for electric-power transmission, including load and fault interrupting switches; reclosers; sensors; system protection equipment; power grid automation; transmission and distribution cable terminations; and joints and other cable accessories.
Having invested in an FBO-III flaskless molding operation in 1996, G&W's decision to adopt a new Sinto moldmaking and mold-handling installation reconfirmed its confidence in the brand and its capabilities.
The renewed partnership brought access to the Sinto Smart Foundry intelligent process management capabilities too, including local support and the opportunity to access new solutions as needs evolve.
Installing the new molding equipment and process-control technology commenced in November 2023 – and G&W restarted mold production just 14 days after the installation began.
Incorporating Industry 4.0 technology through SSF integration brought real-time process monitoring to the molding operation through the live production monitor; G&W engineers stay informed about the production processes so they’re able to make timely decisions and optimizations. Data is provided immediately and can be customized to include the information that operators, shift leaders, or plant managers need to see.
Derek Wilken, G&W maintenance project manager, described the various objectives behind the investment, including improving safety, ergonomics, and efficiency, while also enhancing finished-casting quality of castings by replacing manual handling with automated production. He noted that G&W’s choice of Sinto was also driven by the project’s turnaround time and installation support, underlining the effectiveness of their partnership.
Since restarting production last November, G&W reports it has doubled mold production rates, from 40 molds/hour to 80 molds/hour, and a substantial 50% reduction in scrap. Moreover, by eliminating various ergonomic and safety issues associated with manual handling the foundry has increased productivity, and improved workplace efficiency and safety, putting it on track to expand production and profitability.