Efficiency comparison

Comparisons of efficiency can always only be designed very individually for the respective casting product. The comparison contained in the following relates to real test series in a case study with the company Litostroj (see case study). Efficiency comparison Comparisons of efficiency can always only be designed very individually for the respective casting product. The comparison contained in the following relates to real test series in a case study with the company Litostroj (see case study). The efficiency of ECOFORM is obvious: EUR 3,710 in material costs were saved on each casting part alone. And the manufacturing time was reduced by 652 hours, i.e. approximately 27 days. The competitive advantage is apparent.

 

The advantages of ECOFORM: a comparison

Of course ECOFORM requires a certain initial investment. The advantages offered by ECOFORM outweigh the costs, however. The following table compares a standard manufacturing process with the ECOFORM concept.

 

SPACE NEEDS
Space needs for production area	Reduced by up to 25 % with ECOFORM depending upon the part being produced
OPERATING RESOURCES
Number of moulding boxes	Moulding boxes are reduced with ECOFORM in line with the cast cooling in small series
Moulding sand	Up to 50 % reduction in the quantity of moulding sand with ECOFORM
Auxiliary mould material	Elimination of the reinforcing bar and support iron, weights and casting beds
Sand quality	The quality of regeneration sand is improved by greater thermal stress and thus a lower annealing loss
ENVIRONMENT
Chemical binding agents	Reduced by up to 50% with ECOFORM in accordance with the lower quantity of sand
Quantity of landfill material	Reduced with ECOFORM by the amount of new sand saved
Energy consumption for sand management	Reduced with ECOFORM in accordance with the quantity of sand
INVESTMENTS
Transport and model platforms	Greater costs for ECOFORM due to torsion-resistant, mechanically processed plates
Special moulding box bar system	ECOFORM requires a special design of the moulding box bar system, causing additional costs
Costs for operating materials	Significantly lower costs for reinforcing bar and support iron and weights
TECHNOLOGY
Logistics	ECOFORM only requires a slight adjustment in the production process
Transport platforms	Preparation for the pouring of cast parts takes place on appropriate bearing plates outside the pouring place in front of the mixer; the freshly cast part is transported directly after pouring to harden – thus allowing a boost in productivity
Process time	Reduced by up to 80% using ECOFORM
Mould stability	Increased mould stability through ECOFORM, through moulding bar box for static stress and sand crust for thermal stress