MADE IN GERMANY SINCE For outstanding mould compound quality. The perfect mix. SAND PREPARATION.

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1 MADE IN GERMANY SINCE 1907 For outstanding mould compound quality The perfect mix. SAND PREPARATION

2 For foundries of the future Thinking ahead. One-of-a-kind system competence Our mission: Leadership in technology Moulding plants Innovative technologies and robust machinery concepts for small or large projects KW YOUR ONE-STOP SHOP KW is your perfect partner when the situation demands economical, first-rate technology made in Germany. Robust, dependable plant and equipment reaffirms our worldwide reputation for over 100 years. We shall continue this journey of shaping the future of this industry since we believe in thinking ahead. Foundry professionals value the over 100 years of innovation and top-level competence displayed by staff at KÜNKEL WAGNER. Technology, precision, efficiency, functionality and product quality are all reflected in the development and production of turnkey foundry solutions, modular systems and their components. This includes everything from an automatic moulding plant to sand preparation, reclamation, pouring equipment along with enhancing process technology. While the above is true the only standard we apply is the one set by our customers. Our competence spans across various sectors; being the best yardstick to measure success. Make your capability a reality: with KÜNKEL WAGNER. For foundries of the future. 2

3 MADE IN GERMANY SINCE 1907 Sand preparation/reclamation Pioneering ideas and flexible solutions for optimal moulded sand quality Service Maximum support by stocking spares & adaptive services to meet all customers needs Pouring machines State-of-the-art machinery for cost effectiveness and process assurance Contents Moving Ahead - with Experience p. 2 3 KW Sand Preparation p. 4 5 KW Plants and Polygonal Screening Units p. 6 7 Thinking ahead: Product technology, development and process knowledge are our USP, which set us apart from our competitors. KW Return Sand Coolers p. 8 9 KW Rotary Mixers p KW Sand Quality Testers p. 12 KW Control Systems p. 13 KW Sand Reclamation p KW Service & Contact Data p. 16 3

4 State-of-the-art plants, products and solutions Sand at its best. 4

5 SAND PREPARATION Sand preparation processes must be expertly conceived & conducted to permit reliable, costeffective and environment-friendly manufacturing. The sand quality achieved depends on the specific processing technologies used. Across-the-board expertise in moulding plants AND sand preparation systems! What is the key to successful sand preparation? The right equipment for the job: highperformance sand processing plants from KÜNKEL WAGNER. Meeting highest standards for moulding sand properties, casting precision and environmental protection. Foundries of the future benefit from our multifaceted expertise. We know all interfaces between the casting manufacturing processes, moulding sand and sand preparation KW Sand Preparation Benefits Leaders in core and green sand separation, specialists in sand treatment and sand reclamation Cross-process know-how High-performance components, assured quality High efficiency, high degree of mulling Extremely reliable, easy to operate, maintenance friendly processes. We understand how to utilise them effectively to set up fully automated, problemfree operation for years to come. KW offers a full know-how package in all process sectors required for reliable sand preparation including sieving, cooling, premixing, storage and homogenisation, in-process checks, mixing, water dosage, storage as well as recycling and reclamation of used materials. KW sand preparation technologies incorporate modular design for adaptability in accordance with the requirements at hand, paving the way for optimum results. Turnkey sand preparation plants are offered as well as individual system components, creating a full range of options for planning ahead. Included are KW process configurations for separation of green sand and core sand, preparation concepts, ideas for saving raw material consumption as well as strategies for quality control, monitoring and online process data management. Trailblazing innovation in new and ongoing development Add-on components available as options 5

6 Personalised designs and features Ideas tailored to your needs. TURNKEY PLANTS Whether the plant supplied is a tower design or configured to fit under existing building heights: our systems provide KW quality without compromises regardless of on-site space availability and climate conditions. Layout / typical tower configuration side view, top view Layout / typical flat configuration side view, top view Legend: 1 Magnetic separator 2 Bucket elevators 3 Polygonal screen / polygonal sieves 4 Intermediate hopper 5 ASK return sand conditioner cooler-mixer return sand / warm 1 6 Centrifugal pre-separator 7 Return sand hoppers 8 New sand hoppers 9 Additive hoppers 10 Sand weighing device 11 Additive weighing device 12 WM mixer 13 Online sand compaction testing device return sand / cooled additives finished sand

7 Know-how at work: KÜNKEL WAGNER polygonal screening units are the most advanced in their category. Our patented moulding sand separation process utilise polygonal screens to separate core sand and green sand as soon as possible, ensuring high efficiency. Immediately after removal from the casting, the used moulding sand passes through magnetic separators and is transferred onward for reclamation. The sand then undergoes granulometric processing by the KW polygonal screening unit which breaks up and removes agglomerates. The polygonal screening unit incorporates an innovative geometric design providing maximum physical strength for the rigourous screening process without need for internal supports. KW is the first manufacturer worldwide to offer polygonal screening units which separate defined sand qualities at the start of the preparation process. Upgrade the efficiency of your sand preparation process: not a problem for KW polygonal screening units. KW separation technologies: return sand processing Substantial reductions attainable in additive contents. The sand in the screening unit is agitated by rotation powered by an externally mounted drive unit. Fine acceptable particles fall through the screen openings whereas coarse particles and lumps are retained and conveyed out. Hot and dry sand is transferred to the sand reconditioning cooler-mixer to be blended with water only and conveyed to storage hoppers whereas moist sand with high bentonite content by-passes the sand cooler. agglomerates hot, dry sand / low bentonite content to reclamation warm, moist sand / high bentonite content to return sand cooler 7

8 KW return sand coolers / continuous-operation homogenisers Optimum cooling. RETURN SAND CONDITIONING Particularly in operations with mould capacity bottlenecks and long cooling times, used sand must be cooled from approx. 200 C to below 40 C as quickly as possible. Hot sand affects almost every aspect of casting operations, leading to losses in quality, efficiency and bottom-line profits. The solution: KW s return sand coolers and their cutting-edge conditioning technology. KÜNKEL WAGNER return sand coolers contribute significantly to optimum sand preparation with top-notch technical benefits and outstanding performance. Although the basic technological principles utilised transport and mixing, moisture addition, cooling by water evaporation, vacuum removal have been the same for decades, KW s solutions provide convincing benefits with innovative features and expert engineering. Successful process technologies the result of long-standing R&D expertise. sufficient residence time and minimum fines extraction. The measurable difference: roughly 5 C lower outlet temperature is achieved as compared to conventional coolers. But that s not all: KÜNKEL WAGNER sand coolers provide other benefits including maintenance-friendly design and long service life of mixing tooling as well as optional features providing automated infeed of suspension-based additives during the cooling process. The special materials of construction used in both mixing tools and the cooling chamber floor as well as optimum dimensioning of the sand bed, moistening system and mixing chamber ensure timely moisture addition, KW return sand coolers: your first choice for efficient cooling and personalised optimisation potential. 8

9 Synergies in research, development and innovation lead to trailblazing ideas. Expertly conceived hopper storage provides blending of individual used sand batches for improved mould properties. engineering. From the people with a passion for sand and a name known throughout the industry: KÜNKEL WAGNER. KW Return Sand Coolers Benefits High throughput capacities, maximum cooling rates Let KW return sand coolers make life easy for you. KW return sand coolers offer high throughputs up to 250 t/h, advanced technology with a proven track record in the industry, integrated user-friendly operating controls and many other tangible advantages. By ensuring constant temperature and moisture content of outlet sand, they provide best possible conditions for subsequent process steps. As a result, the process runs smoothly, providing high-quality castings with outstanding cost efficiency. Superb quality powered by smart Efficient water metering with precision of ± 0.2 % Highly reliable homogenisation Electronically controlled sand output gate Stabilised sand output rate, constant volume of sand in cooler Integrated fully automated control system Maintenance-friendly design Special dosage processes available as optional features 9

10 FINISHED SAND PREPARATION Our high-performance batch rotary mixers are cost-efficient. They are the best available in their field and the KEY component in sand preparation plants. And here s why: Our high-performance sand preparation technology has a recipe for success: the mixer. Not just any mixer. The KW rotary mixer, designed to provide superb performance and rugged reliability in manufacturing practice, day in and day out. The 250 mixers we have supplied to foundries worldwide over the last 25 years are our best calling cards. The KÜNKEL WAGNER name stands for expertly processed moulding sand and extensive know-how in pre-mixing, homogenisation, testing and correction of moisture content, final mixing and discharge. When the outlet gate is opened, the compounded moulding sand is ready for use with optimum flow properties, homogeneity and lump-free consistency. Discharging the mixer will make you happy. And rightfully so. Durable, easy-to-change components are used in all areas subject to abrasive wear. When the next mixing cycle begins, KW mixing technology answers the call again, continuing to prove its cost efficiency and reliability in long-term operation. With virtually simultaneous sand infeed and water addition for substantial time savings. With rapid mixing with high-speed impeller tooling. With controlled infeed of additives. With wall-and-floor scrapers ensuring homogeneous mixing and preventing localised dead spots. With high- RPM disagglomeration providing accelerated binder dispersion throughout the blend. KW rotary mixers: for simple, fast and reliable intensive mixing. KW rotary mixers The perfect mix! 10

11 Intensive mixing is a complex process involving continuous rerouting of circumferential sand flow as well as cyclical shear, compression and decompression. In contrast, the results provided by KW mixers are simple: loose, free-flowing sand without lumps. The high standards we set for our mixers are your assurance of optimum performance day in and day out at your plant. Wide range of equipment available for foundries of all sizes. KW Rotary Mixers Benefits Mixing capacities of t/h Intensive mixing process Batch operation with low operating costs Understanding how mixing really works is essential in order to realise the potential in the sand processed. KW knows how to introduce water and additives into used sand as well as how to deagglomerate bentonite in a way which ensures formation of a uniform bentonite film around every sand particle. KW knows the tools required to do the job: rotating wall/ floor scrapers in conjunction with synchronised high-speed impellers. The more we talk about KW rotary mixers, the clearer things become: the exceptional challenges posed by sand call for exceptional mixing technologies and solutions. Get the best solution for your specific application: contact us by phone or mail. High degree of mulling: greater than 95 % Uniform, optimum quality of compounded moulding sand Integrated process control Rugged, service-proven design Rugged construction, clear-cut design. Proven reliability in foundries worldwide. 11

12 FINISHED SAND PREPARATION KW VD 01 compressibility meter Measuring sand quality. Testing of compounded sand: avoiding defects before they can occur in moulding. Visualising sand quality with the compressibility tester from KÜNKEL WAGNER. Gone are the days of relying on foundrymen s judgement or time-consuming lab analyses thanks to this ingenious test device developed by our engineers. Offering superb precision, quick-response correction and full automation to eliminate human error, the KW VD 01 is our advanced testing system for compounded moulding sand. The system takes a sample from the mixer during the ongoing mixing cycle (or directly from the moulding machine) which is used to determine compressibility and compressive strength. Eyeballing is O.K., but testing is better. The KW VD 01 checks the key parameters of bentonitebonded moulding sand to enhance the economics of your casting process. If out-of-spec results are found, water is added as required and the test is repeated. Bentonite is automatically added in accordance with the water dosage. Ambient temperature is also measured and taken into account in the evaluation. All test data are continuously recorded and can be recalled at any point in time. A clear improvement, constant moulding sand quality! And by reducing mould defects, you cut down scrap production as well. 12

13 CONTROL SYSTEMS Control, operation, monitoring Everything under control. The KÜNKEL WAGNER process control and visualisation system provides highly reliable control of your sand preparation operations and process components. This operator-friendly control system controls and records all quality and process-relevant data, including recall capability e.g. for documentation of certification compliance. If other-make control systems are used for moisture and compressibility of compounded moulding sand, they can be integrated into the KW control system. Integration with closedloop control is available as well as preventative monitoring systems. Control centre with modular design. The control system incorporates a wide range of other useful features such as process status messages, diagnostic reports, comprehensive administration of additive dosages as well as other process data and in addition operating capability in either automatic and manual mode. For availability of all important parameters of materials processed in a matter of seconds, for timely provision of important updates, for state-of-the-art Advanced, user-friendly process visualisation. The control system can be equipped with customised databases if desired. performance in all aspects: Go with KÜNKEL WAGNER. 13

14 KW TURBO DRY technology: Reclamation instead of disposal as industrial waste Turning old into new. RECLAMATION % savings potential in waste disposal of used sand! Every year, thousands and thousands of tonnes of used sand are generated by foundries. Full of contaminants and hazardous compounds, the sand represents nothing more than costly garbage. The TURBO DRY system from KW provides substantial benefits: reduced consumption of new sand and additives as well as reduced generation of industrial waste and resultant disposal costs. Like in many other industries, conservation of resources is important in metal foundries due to continually increasing costs of foundry sand procurement and disposal. Responding to this situation, KÜNKEL WAGNER has developed a versatile and highly effective process technology for the reclamation of mineral-bonded used sands and blends. KW TURBO DRY enhances your foundry s ecological and economical performance. cesses. The process cleans the quartz particles extremely gently by use of friction, i.e. without changing their chemical constitution. This highly eco-friendly technology includes filtration of air-borne dust generated in the process. Reclamation is effected by an integrated in-line process with high operating efficiency. Besides providing highest-quality reclaimed sand, KW TURBO DRY is also very cost-efficient with its low energy consumption, low wear and low maintenance requirements. Using this technology, even difficult-to-reclaim sands can be processed for reuse as new sand substitutes e.g. for core production in cold-box, shell moulding, water glass and SO2-set pro- KW TURBO DRY Benefits State-of-the-art reclamation technology Significant savings potential: reduced procurement of new sand and additives, reduced waste disposal costs Highest-quality sand, substitute for new sand Convincingly clean results: photos before and after KW TURBO DRY processing. Extremely gently cleaning of sand grains Superb cost efficiency Low wear & tear, low maintenance Economically viable at rates > 5 t /day

15 Used foundry sand is normally disposed of as landfill waste. Until KÜNKEL WAGNER came into play with cost-effective cleaning by the KW TURBO DRY process. The KW reclamation plant for landfill-free reuse consists of three in-line process units effecting 1) preparation of mixed return sand, 2) TURBO DRY reclamation and 3) postprocessing in accordance with the intended use of the reclaimed sand. The first process unit separates off residual iron debris in the used sand and disintegrates agglomerates, virtually reducing them to individual grains. In the TURBO DRY unit, hot air is used to dry the inlet sand and remove most of the binder components which are recovered for reuse in moulding sand preparation. Then, the sand stream is subjected to a mechanical cleaning process. Next, cold air is used to clean the sand stream until the desired degree of purity is attained. Further processing steps can be integrated into the unit if required. The plant operates econom- ically at throughput rates of 5 tonnes per day and greater. A mobile TURBO DRY plant is available on a rental basis for extended on-site trials. When was the last time you found out about something really new and useful? Here s the next one: cost-efficient and eco-friendly sand reclamation. For further information, please visit:

16 We re available to you anywhere in the world with production sites in Germany, India and China. Our highly acknowledged specialists are glad to support you with comprehensive service at all times: You can reach us round the clock, 7 days a week via our Support Hotline. KÜNKEL WAGNER Germany GmbH Hannoversche Straße Alfeld Tel.: +49 (0) Fax: +49 (0) info@kuenkel-wagner.com kuenkel-wagner.com 24/7 KW SUPPORT HOTLINE for technical support: +49 (0) The right to make changes in construction designs, equipment and content is reserved. The same right applies to printing and other errors. Reproduction, including excerpts thereof, solely with the written approval of KÜNKEL WAGNER Germany GmbH, Alfeld, Germany VI Printed in Germany MOULDING PLANTS SAND PREPARATION PLANTS POURING MACHINES SERVICE