Although COVID-19 outbreak, our offices in Salerno, U.S.A., India, Mexico and Australia are open.
All production operations are normally performed in our manufacturing plant and our Construction & Commissioning team keeps working to offer customers all needed technical support.
Magaldi Power will keep operating worldwide with part of our engineers and employees in office and part working remotely on Smart Working basis, our team will continue to support you with the same passion and commitment as always.

STEEL BELT CONVEYORS FOR SEVERE CONDITIONS since 1929

Evercast

THE CHALLENGE

After the valuable experience gained with the GIS group for the plant of Tisamatic, Magaldi was involved in a project to cool down castings with the requirement to place the MCC® (Magaldi Casting Cooler) in a very narrow space due to layout constraints of the existing foundry.
This was a reason to study and develop an enhanced casting cooler that could provide the same benefits and performance of the MCC®, but with a shorter length: this is the so called SuperMCC®.

 

THE CUSTOMER

The Grupo Industrial Saltillo (GIS) and the ZF-TRW Company inaugurated the Evercast's new plant in Irapuato, Guanajuato (Mexico) with a USD 120 million investment. The Company, dedicated to the foundry and machining of automotive parts, produces nodular-iron security components such as calipers, brackets and adaptors for the automotive braking systems.
The plant was installed a few meters away from its "sister" Cifunsa Irapuato and has a capacity of 50 thousand tons from a vertical Disa molding line.

 

THE SOLUTION

The first stage of the project was for a single line that should be doubled in the next few years.
The SuperMCC® is fed by a short vibrating feeder installed downstream of a Didion drum. This vibrating feeder allows for a correct distribution and placement of the castings on the SuperMCC® to comply with the resident time identified for each group of castings.
The SuperMCC® is provided with the Magaldi Integrated Supervision System (MISS®) in order to optimize the cooling performance for each different type of production and to minimize the energy consumption for the cooling process. The conveyor is equipped with a 20-meter cooling tunnel, held under a negative pressure by a venting system. A Magaldi spill chain is installed underneath the main conveyor to recover the sticky sand that may remain attached on the steel pans and carried back. Moreover, a rotating brush is installed in the lower part of the conveyor head section to clean up the belt and its air slots.
The MISS® manages and controls the cooling air flow according to the inlet temperatures of the castings and adjusts the belt speed to meet the design residence time as a function of the various types of castings to be cooled down. The castings come from the Didion drum at about 570 °C and are cooled down to approx. 60 °C. The cooling performance of the SuperMCC® is one of the guaranteed parameters.
The SuperMCC® installation at the Evercast foundry in Irapuato provides the following main benefits compared to a conventional vibrating cooler:

 

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