Modernizations and upgrades for German foundry Schönheider Guss – boosting production efficiency thanks to state-of-the-art technology from Eirich
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Schönheider Guss, a long-established German company in the foundry industry, has comprehensively modernized and upgraded the production control systems for its molding material preparation line in order to improve line performance, output and production reliability. Maschinenfabrik Gustav Eirich was tasked with implementing these modernization measures and installed new control technology as well as a control module for optimization of sand distribution.
These new developments and upgrades will help boost efficiency and make production more reliable.
- New control system for increased efficiency and improved control
The originally installed control system dated back to 1999 and was outdated. This meant that it was no longer up to the task of meeting modern production requirements. To bring the system up-to-date, Eirich replaced the old Siemens S5-135U automatic controller with a modern S7-1515 unit. In the process, all the I/O modules were equipped with new Siemens components. This change has resulted in improved performance with higher output, and it also allows for more precise control of the production process. In addition, spare parts are now readily available again for the new system.
- Optimization of mixing and distribution technology
The technology for the mixing process and for molding sand distribution was also comprehensively modernized. Thanks to a new moisture probe and an overhaul of the water weighing unit with a new dosing device, water addition has been optimized and is now even more precise to ensure consistently high sand quality. One area that was of key importance was the introduction of an intelligent sand distribution system. This unique technology from Eirich provides the molding machine with exactly the required amount of freshly prepared molding material – just-in-time and with consistently high quality assured at all times.
- New visualization system and upgraded user interface
In order to make the system more user-friendly, Eirich integrated a new process visualization system with an ergonomic user interface and updated the SandReport app to the latest version, which offers detailed insight into the production processes and production data. The new visualization makes work easier for operators by providing them with a more intuitive way to control the system. All process data can now be tracked more readily, allowing the data to be used to continuously improve operating processes and workflows.
The modernization was completed within a very short space of time and was planned so that the line could be taken back into operation again on-time after the end of the company's scheduled shutdown for the summer break. Thanks to the planning and implementation by Eirich, disruption of the production processes was kept to an absolute minimum, ensuring that Schönheider Guss was able to integrate the new systems quickly and effectively back into its regular operations.
Investments in the future: improved efficiency and more reliable production
The comprehensive modernization of the system has led to a significant increase in output and has helped to optimize workflows. With seamless documentation of batch records, traceability has now also been simplified in the event of irregularities to boost long-term process reliability.
“We have a highly detailed understanding of the specific requirements of molding sand preparation and have been working very closely with foundries all around the world for many years. Our skills lie not only in the planning and construction of large, complex systems, but also in working out ways in which even small changes can help achieve significant gains in efficiency. Here, control systems using the latest digitalization solutions offer considerable leverage for improvements. As a result, we are able to help long-standing, traditional companies like Schönheider Guss by modernizing their equipment and achieving impressive efficiency gains even on lines where the existing systems and engineering are older. This enables them to comply with the latest regulations and requirements more cost effectively, helping to ensure that they remain competitive.”
Selective investments and modernizations of sub-systems and small but carefully-targeted retrofits can bring outdated technology right back up to date with minimal effort and manageable costs. The use of smart control technology combined with innovative software solutions can deliver long-term improvements for production processes. In the process, Eirich has proved itself to be a dependable partner who not only truly understands the unique requirements of the foundry industry thanks to its decades of experience in the field, but who can also offer individual solutions tailored to the unique needs of each client.