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DISAMATIC C3-350s deliver millions of moulds with superb quality, speed and uptime

After a leading Chinese compressor casting manufacturer’s first DISAMATIC C3-350 arrived in December 2017, this green sand, vertical moulding line produced 10 million moulds within the first five years – and has now produced over 15 million moulds. The C3’s very fast pattern changes and low maintenance added over two hours extra production time per day compared to the (non-DISA) moulding machine that it replaced.

Despite its demanding 24/7 schedule and 2200-ton monthly output, this company’s first C3 continues to deliver extremely high uptime and a very low 1.2% scrap rate. Fitting original parts and choosing DISA service support are two reasons for its outstanding performance and reliability – which inspired this company to install a further three C3-350s at its Ma’anshan facility in Anhui province.

“The performance of the first C3 at Guangzhou gave us the confidence to buy more DISA machines,” says the General Manager of Ma’anshan facility. “Original DISA parts are accurate and stable after replacement, that’s the main reason we only fit original parts.”

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DISAMATIC C3s take over production

Founded in 2011, the Ma’anshan foundry mainly produces compressor castings. The facility installed a DISAMATIC C3-350 machine in January 2019 and, by August 2024, this line had produced over 10 million moulds in just five years. It runs 24/7 and only stops for 12 hours each month for scheduled maintenance. The entire line is DISA-supplied, including the complete sand plant.

Once again, this second C3-350 had reached this huge 10-million-mould milestone in less than five years.

The third C3-350 started its 24/7 production life in November 2023, replacing the previous non-DISA line. At around 1.5%, the all-DISA line’s scrap rate was immediately 1% lower than the old machine.

“The new moulding machine produces an extra 2000 tons annually and requires no extra maintenance,” says the foundry manager. “DISA has a good service team and excellent quality spare parts. We will always work with DISA.”

Time and time again, Brackelsberg’s versatile moulding line has proved its speed and all-round ability, producing everything from gearbox housings to lift and sewing machine components in varying run lengths.

“We run all kinds of castings that fit on our DISA’s plates,” says Martin-Mohaupt, “producing small and medium series in different materials for a really diverse range of industries. We added a superstructure to the Automatic Mould Conveyer (AMC) plates in order to raise casting weight up to 40 kg per mould but, other than that, we’ve not changed it much in 50 years.”

“Our DISAMATIC has run and run for us without any major downtime and its robust mechanical design meant we were always able to rectify any faults ourselves,” continues Martin-Mohaupt.

Makes every line a DISA line

The fast-growing Ma’anshan foundry will install yet another DISAMATIC C3-350 later this year. This fourth line will replace an old non-DISA vertical machine and be fed from the sand plant on its second DISA line. When it goes into production, every single line will be a DISA line.

“Compared to our old machine, we know our fourth DISAMATIC C3 will require less maintenance, be faster and produce better quality castings,” says the foundry manager. “With DISA, the quality of the products produced is stable and the equipment has a lower failure rate.”

Speed plus quality, made in China

Available in three speeds (up to 350 uncored moulds per hour) and in three sizes, the DISAMATIC C3 can produce a wide variety of castings in various formats and alloys. The DISAMATIC C3 offers maximum performance for minimum investment and a high ROI over a long service life. It is made locally at DISA’s dedicated manufacturing facility in Changzhou, China, with short lead times and local technical support.

“We first chose DISA because we trusted the brand, but their high-quality service and excellent products gave us the confidence to continue using C3s,” says the foundry manager. “DISA gives customers what they need, not only the equipment itself but also aftermarket service, technical support and machine and application training for customers. We recommend DISA to other foundries looking for high quality.”

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DISAMATIC C Lines

About DISA

DISA, a Norican Group technology, develops and manufactures a complete range of metal casting production solutions for the ferrous and non-ferrous foundry industries. Headquartered in Taastrup, Denmark, DISA is the world-leading supplier of complete foundry solutions and services, as well as state-of-the-art green sand moulding equipment.

DISA also offers its class-leading Monitizer digital solutions to support the whole digital journey from data collection to AI-driven casting quality optimisation. Monitizer works in all types of foundries and processes, and with any vendor equipment, to deliver serious process improvements – fast.