New Molding Equipment Investment Brings Significant Benefits to Manufacturer’s Brass and Aluminum Foundry

May 1, 2024 Grand Ledge, MI

Manufacturer’s Brass and Aluminum Foundry’s (MBAF) investment in the new Sinto FBO-III 20×24 flaskless molding machine with mold handling line and Sinto Smart Foundry integration has brought about significant improvements in their operations. The integration of Industry 4.0 technologies like the Sinto Smart Foundry system has allowed G&W Electric to enhance their foundry processes, bringing about benefits such as improved safety, efficiency, and quality.

Manufacturer’s Brass and Aluminum Foundry, a division of G&W Electric, boasts a rich history spanning over 70 years.

Since 1905, G&W Electric has been a leading provider of innovative power grid solutions including the latest in load and fault interrupting switches; reclosers; sensors; system protection equipment; power grid automation; transmission and distribution cable terminations; and joints and other cable accessories. G&W Electric is headquartered in Bolingbrook, Illinois, U.S.A., with manufacturing facilities and sales support in more than 100 countries, including Canada, Italy, China, Mexico, Brazil, India, UAE and Singapore. G&W helps their customers meet their challenges and gain a competitive edge through a suite of advanced products and technical services.

Having previously invested in Sinto technology back in 1996, with their first Sinto FBO-III, MBAF’s decision to partner with Sinto once again reflects their confidence in the brand’s capabilities. Through this partnership, G&W Electric has gained access to Sinto Smart Foundry integration, localized support, future growth opportunities, and potential solutions for their evolving needs.

The incorporation of Industry 4.0 technology through Sinto Smart Foundry integration represents a significant leap forward for G&W Electric, taking their foundry to a new level. With real-time monitoring through the Live Production Monitor, G&W engineers can stay informed about their production processes, enabling them to make timely decisions and optimizations. This data is provided immediately and can be completely customizable to the information the operators, shift leads or plant managers need to see.

Derek Wilken, MBAF Maintenance Project Manager, emphasized the various objectives behind the investment, including improving safety, ergonomics, and efficiency, while also enhancing the quality of castings through automation vs. manual handling. The choice of Sinto was driven by considerations such as turnaround time and installation support, underlining the effectiveness of the partnership.

The installation of the new molding equipment and Industry 4.0 technology commenced in November 2023, with MBAF swiftly initiating production just 14 days after installation began. Since then, MBAF has witnessed remarkable improvements, including a doubling of mold production rates, from 40 molds/hour to 80 molds/hour, and a substantial 50% reduction in scrap. Moreover, the elimination of ergonomic and safety issues associated with manual handling has further increased productivity, efficiency and workplace conditions, enabling MBAF to expand their operations and increase revenue.

Sinto expresses gratitude for MBAF’s trust in their equipment and is pleased to see the positive outcomes that MBAF has achieved since the installation. By mitigating safety concerns, enhancing reliability and capacity, and addressing quality issues, Sinto anticipates MBAF to continue prospering through the utilization of advanced foundry solutions.

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