Features | Foundries, Forges and Die-Casting

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Foundries, Forges and Die-Casting

Sizable trunnion cast for SAG mill breakdown

By: Halima Frost 8th March 2024 Mill roll and ring manufacturer South Africa Roll Company (Sarco) has delivered what it believes to be the largest locally cast semi-autogenous grinding (SAG) mill trunnion casting to grinding mill manufacturer New Concept Projects (NCP). NCP needed the cast for a client that experienced an... →

New owners of precision casting company drive technology, skills investment

By: Marleny Arnoldi 8th March 2024 Following a takeover of Rely Precision Castings by a new group of shareholders, the company is undergoing a renewed market expansion drive with investment into technology, and development of a skills pipeline. →

PRECISE CAPABILITY Rely is capable of rapid prototyping and undertaking small-scale manufacturing according to customer needs

AI tech reduces foundry’s energy consumption

8th March 2024 Danish iron foundry Birn announced in December it had completed an artificial intelligence (AI) project in cooperation with automatic pouring technology developer and manufacturer Pour-tech AB to optimise dosing of molten iron from casting machines into moulds. The project aimed to reduce energy... →

New analysers launched at Indaba

By: Halima Frost 8th March 2024 International elemental analysis company Innov-X Africa has taken delivery of the newly launched Vanta Max and Vanta Core X-ray fluorescence (XRF) analysers, which were showcased at this year’s Investing in African Mining Indaba, held in Cape Town last month. The company also plans to promote... →

The newly launched Vanta Max and Vanta Core X-ray fluorescence (XRF) analysers one blue and one yellow

NEXT-GEN PRODUCTS The new Vanta Max and Vanta Core X-ray fluorescence analysers being distributed by Innov-X Africa were launched at this year's Investing in African Mining Indaba

Dry ice blaster popular in cleaning applications

By: Halima Frost 8th March 2024 With more than 30 units of the Intelblast (IBL) 3000 having been sold to foundries, forges and die-casting companies across South Africa, blasting machine manufacturer Dry Ice Blasting Services continues to maintain its foothold in the sector. More than 200 of the industrial-sized dry ice... →

The new IBL 3000 dry ice blasting machine sold by Dry Ice Blasting Solutions

AS DRY AS ICE The use of solid carbon dioxide, or dry ice, reduces wet waste during the cleaning for foundries, forges and die-cast companies

Company’s new furnaces under scrutiny

10th March 2023 Luxemburg-based ArcelorMittal’s path to net zero emissions has come under scrutiny as it starts the construction of a new coal-based blast furnace in India which contrasts with low-carbon steelmaking in Europe and Canada. In a report released last month it was suggested that ArcelorMittal should... →

ArcelorMittal's brazil furnace operations image supplied by Bloomberg

NOT SO GREEN The fact that ArcelorMittal continues to build coal-fired furnaces has come under the microscope

Furnace adaptation can greatly reduce emissions

10th March 2023 Researchers from the University of Birmingham, in the UK, have designed a novel adaptation for existing iron and steel furnaces that could reduce carbon dioxide (CO2) emissions from the steelmaking industry by nearly 90%. →

OLI South Africa

10th March 2023 OLI is the world’s top-selling supplier of electric external motovibrators. The OLI product is distributed in Southern Africa by its subsidiary in Gauteng, South Africa. →

Two furnace tech providers join forces

10th March 2023 Parts formation provider Norican’s Monitizer platform and furnace equipment supplier ABP’s Digital Services announced an agreement had been made in February to interface their products in an effort to advance foundry digitalisation. Monitizer and ABP Induction Systems will build links between... →

An ABP Induction services furnace in operation with man in PE near molten metal

FURNACE INTERFACING Norican and ABP Induction are joining forces to make furnaces more efficient

Continued research makes for better die-cast materials

By: Halima Frost 10th March 2023 Steel and technology group Voestalpine boasts a strong footprint in the supply of metals used in various die-casting applications and strives, through continuous research, to further expand its product and reach in South Africa and Africa. The company says researchers at its mills, in Austria and... →

A concept image of a car engine which is due to be used as a template for a Die-set, against a blue background

CASTING CONCEPT The new materials constantly being developed by Voestalpine not improve the quality of end product but also the life of the die-sets as well

New burrs designed for foundries

By: Claire O'Reilly 11th March 2022 Abrasive tool solutions developer, manufacturer and supplier PFERD offers a range of tungsten carbide burrs, specifically designed for the foundry and castings industry. →

Company plans to expand wear parts market locally

By: Claire O'Reilly 11th March 2022 High chrome white iron foundry Mitak is celebrating its fiftieth birthday this year, and plans to expand its reach locally in the coming 10 years. →

New contract pushes company towards one-stop-shop goal

By: Claire O'Reilly 11th March 2022 Foundry and heavy engineering company Thos Begbie has been awarded a consecutive contract to do more component installations for the Sibanye-Stillwater platinum smelter plant, in the North West. →

Company projects growth in die-casting sector

5th March 2021 The new aluminium die-casting machinery market research from global technology research and advisory company Technavio indicates neutral growth in the short term as the business impact of Covid-19 spreads. The company expects the aluminium die-casting machinery market size to grow by... →

Range presents various benefits, longer life span

By: Mc'Kyla Nortje 5th March 2021 Engineering components provider BMG’s range of high-performance NSK spherical roller bearings is perfectly suited to operate in demanding environments, including foundries, forges and die-casting applications. The NSK HPS range, which has a life span nearly double that of conventional bearings of... →

HERE FOR A LONG TIME NSK HPS range, which has a life span nearly double that of conventional bearings of the same size

New partnership aims to provide AI operators to iron foundries

5th March 2021 Last month, Swedish computer software company Viking Analytics and automatic pouring systems manufacturer Pour-tech AB announced a partnership to offer artificial intelligence (AI) operators to iron foundries. Viking Analytics notes that its solution, named EASYpour, uses data analytics and... →

BETTER AND BETTER The production environment in a foundry is increasingly changing, demanding several adjustments to maintain the quality of the product

Acquisition ensures unique customer solutions delivery

5th March 2021 Following aluminium die-castings supplier Walker Die Casting’s acquisition by automatic transmissions manufacturer Allison Transmission, over sixty years of know-how and substantial infrastructure improvements have already resulted in considerable benefits for customers. “Since being acquired by... →

ALL ABOUT IMPROVEMENTS Allison has made a substantial investment in Walker Die Casting, which has been used for infrastructure improvements, added capabilities and expanded available solutions for customers

Frankwen Forge

2nd March 2021 Founded in 1981, Frankwen Forge has grown into a key manufacturing and engineering business. Its quality products and services are used in a number of industries, including the mining, petrochemicals, power generation, marine and general engineering sectors. Frankwen Forge has a unique and... →

Company to improve processes with new furnaces

By: Cameron Mackay 6th March 2020 Local metalworking company Thomas Foundry is set to improve and increase the efficiency of its metalworking and manufacturing processes with the purchase of four new induction furnaces. The order was placed in September last year to replace three decommissioned furnaces – a 1 t furnace and two 5... →

FORGING AHEAD The company has purchased 4 new furnaces to reduce electricity consumption, improve quality and productivity, improving environmental compliance and reducing maintenance costs

Localisation to boost industries

By: Cameron Mackay 6th March 2020 Government’s intention to increase demand for locally manufactured content to at least 60% across industries will have a positive impact on the local casting, forging and machining sector, says nonprofit entity the Casting, Forging and Machining Cluster (CFMC) of South Africa project leader Steve... →

CLUSTER COLLABORATION The CFMC is a development purposed vehicle which will enable companies to work together to achieve what could not be achieved individually

4IR, rail projects can grow local foundries industry

By: Cameron Mackay 6th March 2020 The local foundries, forges and casting industry can benefit from following the global trend of metal casting companies implementing Fourth Industrial Revolution (4IR) technologies. An abundance of infrastructure projects, such as rail projects from State-owned rail utility Transnet, has the... →

GLEN DIKGALE There are opportunities for the local foundry industry. Government is increasingly talking about sourcing equipment locally, so we need to comply with requirements

Local foundry leads to AI partnership

By: Cameron Mackay 6th March 2020 With a strong focus on growing its international business, machine learning solutions provider, DataProphet, has signed a partnership with a leading metallic parts enhancement company, Norican Group, to accelerate the adoption of artificial intelligence (AI) in the foundry industry. This came... →

SMART FOUNDRIES The aim is to improve manufacturing processes using AI in the foundry industry

BMG procures foundry to enhance its services

8th March 2019 Technical solutions provider BMG is now a major player in the foundry industry after its acquisition of the iron foundry Rustenburg Engineering and Joerg Foundry last year. “This strategic investment enhances BMG’s service offering and broadens the company’s product range to include the supply of... →

SERVICE OFFERING The acquisition will enhance the company’s service offering and broadens BMG’s product range

Thos Begbie branches out into Zambia, builds local skills

By: Mc'Kyla Nortje 8th March 2019 Foundry and engineering company Thos Begbie has completed the registration of the company for its new branch in Zambia, which it plans to officially open later this year. “We have secured a workshop facility and all the necessary tools to set it up, while Thos Begbie sales director Piet du Preez... →

INTERNATIONAL STAGE Thos Begbie exhibiting at an international trade means exposure for South Africa and strengthens international trade relations

Upgrades to start at Heavy Bay foundry

By: Mc'Kyla Nortje 8th March 2019 In line with its oil sands business growth, engineering solutions provider Weir Minerals Africa has received capital expenditure approval worth R30-million for upgrades at its Heavy Bay foundry in Port Elizabeth, in the Eastern Cape. Significantly, the foundry supplies castings across the globe... →

MORE PRODUCTION Weir Minerals has invested R30-million upgrade at the Heavy Bay foundry in Port Elizabeth

Automated systems reduce production waste

9th March 2018 The implementation at one of the largest foundries in the South Africa of supervised and unsupervised machine learning capabilities produced a 0% external scrap rate, saving the manufacturer as much as R10-million a month, explains business management consultant Dataprophet cofounder Daniel... →

Continued growth predicted for global forging markets

9th March 2018 Market research company Technavio has predicted the global forging market will exhibit a healthy compound annual growth rate of about 4% between 2017 and 2021. The company says the rising demand for fabricated metal products is one of the primary drivers for market growth. Press machines are... →

Photo by Duane Daws
GROWTH The forges markets across the world will continue to grow in the next few years

Forging and steel industries both affected by unpredictable steel price

By: Victor Moolman 9th March 2018 Owing to the volatile and unpredictable steel price from local raw steel mills, the steel industry is looking less to locally-forged parts and equipment, and more to imports, says steel supplier and processing company Allied Steelrode. “As an industry – and in common with the forging industry –... →

Photo by Duane Daws
STEEL FORGED Not all of the steel required in South Africa is economical to produce in the country

Process control manufacturer expands sales to South Africa

9th March 2018 Die-casting process control systems manufacturer Visi-Trak Worldwide has expanded its direct sales distribution to several countries, including South Africa, Australia, Canada, New Zealand and South Korea and to South-East Asia. The company explains that this expands upon its current network of... →

Company becomes exclusive dealer in Rosslyn area

By: Victor Moolman 9th March 2018 Steel supplier BBD steel, in Rosslyn, Pretoria, has become steel supplier and processing company Allied Steelrode’s exclusive distributor of Allied Steelrode Stretcher Material (ASSM) for the area. BBD Steel supplies ASSM products to car manufacturers that are located in the Rosslyn area. BBD... →

BBD Steel MD Monika Pretorious and business development director Gwen Mahuma discuss the importance of ASSM steel and how BBD Steel started. Camerawork: Nicholas Boyd. Editing: Christo Greyling.

Die-caster prepared for next growth cycle in industry

10th March 2017 An increasing number of car parts such as engine blocks or structural parts are being manufactured from aluminum using high-pressure die casting, says die-casting technology supplier Bühler Die-Casting. →

Conference to broaden industry’s business opportunities and technology horizons

By: Simone Liedtke 10th March 2017 Owing to foundries in South Africa being isolated in their approach to problem solving, the South African Metal Casting Conference (MCC) will serve as a platform to broaden the industry’s horizons by showcasing new technologies, and providing opportunities for international and local foundry... →

DALMARI MCQUEEN Owing to the interest in exhibition spaces at the 2013 pilot conference, the 2017 MCC will have 28 exhibition stands

Foundry process developer expands wafer-fabrication facility

10th March 2017 Specialty foundry process developer and fabricator Noel Technologies has expanded its wafer-fabrication facility in Silicon Valley by adding square footage and installing additional equipment that boosts its production capacity by 25%. →

EXTENSIVE CAPABILITIES
The foundry’s extensive process capabilities enable short manufacturing lead times while improving device yield and performance

Photo by Duane Daws
EXTENSIVE CAPABILITIES The foundry’s extensive process capabilities enable short manufacturing lead times while improving device yield and performance

Trial castings successfully completed at foundry

By: Simone Liedtke 10th March 2017 Engineering solutions provider Weir Minerals successfully completed trial castings on new materials for the business’s Trio product range at its Heavy Bay Foundry, in Port Elizabeth, last month. →

RAPID PROTOTYPING Investments in the rapid prototyping process have enabled the foundry to make new patterns to manufacture parts

Deep surface salt bath hardening technique offered locally

By: Simone Liedtke 10th March 2017 Diversified manufacturing facility Frankwen Forge is now offering a unique tailor-made salt-bath hardening technique, the company states, explaining that the surface of the item is run through heated molten salt and then undergoes a water quench. →

INCREASED PRODUCTION The facility will be able to produce ingots of up to 12 t in various grades of carbon and alloy steels

Cast process ensures cost-effective production

10th March 2017 High pressure die-casting provides the shortest route from molten metal to completed component and comprises injecting molten metal into a hardened steel mold and allowing it to solidify under pressure before ejection, says casting supplier MRT Castings, based in Andover, England. →

COST EFFECTIVE PRODUCTION
The high pressure die-casting process allows fast, precise cost effective production of components

Photo by Duane Daws
COST EFFECTIVE PRODUCTION The high pressure die-casting process allows fast, precise cost effective production of components

Early signs pointing to recovery in foundry industry

By: Simone Liedtke 10th March 2017 With the foundry industry having been under pressure last year owing to very low levels of economic growth, the drought and continuing import leakage, the South African Institute of Foundrymen (Saif) believes that signs to date this year point towards some form of industry recovery. →

Saif CEO John Davies and Saif president Takalani Madzivhandila discuss the challenges of the foundry industry. Camerawork: Nicholas Boyd. Editing: Lionel da Silva

Forging market for automotive application to be valued at $56-billion by 2022

10th March 2017 Market research company Zion Market Research has published a new report highlighting that the global steel forging market for automotive applications was valued at $41.77-billion in 2016 and is expected to reach $56-billion in 2022, growing at a compound annual growth rate (CAGR) of 5.1% between... →

INCREASED DRIVE
Increasing cars sales are expected to drive the European automotive and automotive components market within the forecast period

Photo by Duane Daws
INCREASED DRIVE Increasing cars sales are expected to drive the European automotive and automotive components market within the forecast period

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