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Helping in Foundry layout

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  1. #1
    abuyonos started this thread.
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    Helping in Foundry layout

    Hello all:



    I need to establish a small foundry to produce hammers of Cursher from iron scrap.
    Capacity of foundry is 500kg with power of 300kw.

    Can anyone help me in :
    (1) design of layout of foundry,
    (2) needed equipments and device, and
    (3) flow chart of processes ?

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  3. #2
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    Hi and welcome to the forum from Las Vegas! I have exactly zero useful experience to offer but this certainly sounds like a fascinating project and I wish you luck!

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    kss's Avatar
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    500kg/1100lbs doesnt seem like all that big of a foundry is needed. Thats about 50 car rotors of weight. Stacked up, that could fit in a 3'x3' easily.

    I also dont know anything about this so im just making stuff up.

    I would just contract out an existing foundry I would think

  6. #4
    alloy2 is offline Metal Recycling Entrepreneur
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    Quote Originally Posted by abuyonos View Post
    Hello all:

    I need to establish a small foundry to produce hammers of Cursher from iron scrap.
    Capacity of foundry is 500kg with power of 300kw.

    Can anyone help me in :
    (1) design of layout of foundry,
    (2) needed equipments and device, and
    (3) flow chart of processes ?
    Umm, a fellow can dream.

    In your claim to use iron scrap to manufacture mill hammers tells me you know very little of the foundry you wish to set up.

    First off your asking your question in the wrong place, you should be consulting with a sales representative from a company that sells induction furnaces.

    Any number of those company's selling induction furnaces would love to have you as a client as there are consumables which will need replacing.

    For a furnace of that size you'll probably need to obtain EPA certification, ya know comply with the clean air act.

    The largest induction furnace that will operate from single phase electric power is 15KVA and it's only has enough power and crucible size to do an 8 pound copper melt.

    But the furnace melt that 8 pounds of copper in less time than it takes to reheat a cup of coffee in the microwave.

    Hammer Materials: Manganese and Alloy Steel Hammers


    December 12, 2014


    There has been a definite change in the types of scrap being shredded these days. We are seeing much lighter scrap as everyone who has a shredder has noticed and more non-metallics.

    The old days of 15 to 20% loss in white goods and 25 to 30% loss in autos are long gone. Baled sheet metal is more common as shredders reach further out for material. More powerful balers generate hard hitting bundles that test your hammers and keep the motor working hard.


    So which kind of hammers should you use?


    Manganese steel hammers basically have been around since the shredder was invented. Manganese is still the hammer of choice for the vast majority of shredders around the world. It is usually the lowest cost per processed ton performer and the most forgiving with baled and heavy scrap. If your product mix has a good percentage of heavier scrap to shred, you will be able to work harden the hammers for excellent wear. For best results, manganese hammers should have a minimum 1/2% Molybdenum (moly).


    Alloy steel hammers, both UHT and DHT types are up and coming products targeting the shredders with lighter gauge scrap to process. Be sure you compare the higher costs of the alloy hammers versus the increased tons of processed material. For instance, if you are getting an additional 50% increase in tons out per set, and you are paying almost double the cost, does it make sense for your operation? Even with the labor savings from delayed hammer changes, you may still save money with manganese.


    Forged hammers are the newest and most expensive type in the market today. They are a hard hammer, so you will need to have special hammer pins as well. Otherwise you will wear your normal pins out much sooner. Monitor it closely to see if your cost to shred comes down as much as you anticipated. We are hearing double or more the wear life compared to manganese. Gather all costs, so you can compare the hammer cost per ton with pins included. While an improvement, it may not be as much a savings as anticipated. Only your numbers will lead to the right answer.


    K2 Castings produces manganese and alloy hammers for all sizes of shredders. Our suggestion is to test them both and settle on the type which works better for your product mix. If you have any questions or need some help figuring out which is the most cost effective for you, let us know. We will be happy to help you out.
    Last edited by alloy2; 11-08-2020 at 08:47 PM.
    The art of survival is a story that never ends. American Hustle.

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    abuyonos started this thread.
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    Thank you for your replies...

    I studied economic side for this project.

    I have few informations about industrial side.
    So, i need:

    (1) design of layout of foundry,
    (2) needed equipments and device, and
    (3) flow chart of processes (included Quality control points).

  9. #6
    alloy2 is offline Metal Recycling Entrepreneur
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    Quote Originally Posted by abuyonos View Post
    Thank you for your replies...

    I studied economic side for this project.

    I have few informations about industrial side.
    So, i need:

    (1) design of layout of foundry,
    (2) needed equipments and device, and
    (3) flow chart of processes (included Quality control points).
    Our forum is made up from people who collect and sell scrap metals, when you decide to buy manganese scrap we're here to service your needs.

    Arrange a visit with Mount Baker Mining and Metals, Jason recently added a metal foundry to his portfolio and you'd never guess what their main product is.

    If you said hammers for the mills they sell, go to the top of your class.

    I'm not to sure how anxious Jason would be about giving you free consulting but no harm in asking.

    ]Mt. Baker Foundry LLC is a Washington Wa Limited-Liability Company filed on January 17, 2019. The company's filing status is listed as Active and its File Number is 604387039.

    The Registered Agent on file for this company is Jason Gaber and is located at 5421 Guide Meridian Bldg C, Bellingham, WA 98226.

    The Registered Agent on file for this company is Jason Gaber and is located at 5421 Guide Meridian Bldg C, Bellingham, WA 98226.

    Next thing you'll be asking our forum members to contribute to your start up company.

    Last edited by alloy2; 11-16-2020 at 11:14 PM.

  10. #7
    alloy2 is offline Metal Recycling Entrepreneur
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    Quote Originally Posted by kss View Post
    500kg/1100lbs doesnt seem like all that big of a foundry is needed. Thats about 50 car rotors of weight. Stacked up, that could fit in a 3'x3' easily.

    I also dont know anything about this so im just making stuff up.

    I would just contract out an existing foundry I would think
    You and I don't always see eye to eye, but that is excellent advice you've given to the op.

    Operating a foundry is more involved than just tossing bits of scrap metal into a pot, every foundry has a laboratory with metallurgists tracking the consistency of the alloys used in their castings.
    Last edited by alloy2; 11-16-2020 at 11:12 PM.

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    I question how did you study the economic side without knowing what you needed? Just because you saw the price before and after doesn't mean you studied it. Then again, I'm getting a hint of "I will buy all your overseas shipping containers filled with HMS #1, as much as you can supply" vibe from this.


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