Automation has dramatically transformed the landscape of various industries, and the foundry sector is no exception. Foundry automation involves integrating advanced machinery, robotics, and artificial intelligence (AI) into the entire foundry process to optimise efficiency, safety, and mould quality.
The advent of Industry 4.0 and its application in foundries has reshaped traditional practices, enabling smarter operations and contributing to the emergence of "foundries 4.0." This report delves into the history of foundry automation, explores its benefits, and highlights the role of Omega Sinto in this automation revolution.
The Evolution of Foundry Automation
Foundries, historically labour-intensive and dangerous, have evolved parallel to technological advancements. In the early days, workers would manually handle high-temperature molten metal and performed physically arduous tasks. This led to significant safety hazards and potential inconsistencies in casting quality. As the industrial revolution progressed however, mechanisation and automation began to take shape.
Technological advances within the foundry automation have been occurring since the 1950s (
1). These early automated systems mostly involved mechanised handling, material movement, and moulding operations, which reduced the need for manual labour and mitigated some safety risks. The inclusion of automated material movement also allowed for a large uptick in production as the option of mass production begun to be possible. However, it’s important to note that foundry workers still played a critical role in machine oversight and the overall operation of the foundry during this time.
In recent years, Industry 4.0, primarily characterised by the integration of cyber-physical systems, the Internet of Things (IoT), and AI, has led to a new era of automation in foundries. Modern systems are designed to autonomously perform repetitive tasks like pouring, cutting, and grinding, with minimal human intervention.
It is fairly evident to suggest that automation does and will continue to play a significant role in the advancements of foundry operations, predominantly through the reduction of human labour and overall efficiency of the operations (
2) (
3).
The Benefits of Automation in the Modern Foundry
The introduction of Industry 4.0 or the “Fourth Industrial Revolution” within Foundry automation offers numerous advantages that have proven beneficial to the industry:
1. Increased Efficiency and Productivity
Automation minimises bottlenecks in production processes. Tasks like pouring molten metal into moulds, trimming, grinding, and handling materials that were once manual now operate continuously without interruption. As a result, production cycles are faster, and downtime is minimised. For illustration, foundries have reported to have seen an increase in overall production by around 15% in recent years (
4), which is arguably symptomatic to these developments in automated processes.
2. Enhanced Accuracy and Quality Control
Automated systems bring a high level of precision to the casting process. Robotics and AI-driven systems can consistently produce parts with tighter tolerances, reducing the amount of scrap material. Moreover, the inclusion of automated systems, most notably for continuous autonomous pouring, has seen a reduction in scrap by 40% or more in multiple foundries (
5).
3. Lower Operational Costs
While the initial investment in automated machinery may be high, the long-term savings are substantial. Automation reduces the need for manual labour and improves resource utilisation. By optimising processes through automation, foundries can save on raw materials, energy consumption, and reduce rework costs due to fewer errors?.
4. Improved Worker Safety
With a reported 70,000 injuries in the steel and iron foundry markets alone (
6), it is reasonable to suggest that foundries can be quite hazardous for employees. Automating dangerous tasks such as molten metal handling and material movement can drastically reduce the incidence of workplace injuries.
5. Adaptability and Flexibility
With the arrival of Foundry 4.0 and automated foundry systems, foundries can now quickly adapt to changing market demands. Automated systems can be reprogrammed to manufacture different parts, making it easier to switch between production runs without significant downtime? and employee training. In a market where availability is key in gaining a competitive advantage (
7), automation serves a key role in guaranteeing the success probability of a foundry.
Related: The Benefits of Automation in the Modern Foundry
Omega Sinto’s Role in the Automation Revolution
As a key player in the foundry automation landscape, Omega Sinto has contributed significantly to the modernisation of foundries across the globe. Specialising in manufacturing advanced equipment for sand moulding and casting processes, Omega Sinto has been at the forefront of enabling foundries to improve their processes through automation.
1. Pioneering Smart Systems and Foundry 4.0 Initiatives
Omega Sinto’s systems integrate seamlessly into modern foundries, offering solutions that enhance both productivity and quality. Our creation of Omega Sinto Connect is our key driver in this area.
Omega Sinto Connect is a web-based monitoring system that incorporates state-of-the-art technology to link Omega Sinto control panels to the cloud; enabling our equipment to be monitored and adjusted remotely, anywhere in the world via web browser access. This system autonomously monitors your production status to allow efficient fault finding and more efficient operation foundry operations
2. Robotic Integration and Automated Solutions
Robotic systems are a cornerstone of Omega Sinto’s automation solutions. By deploying our robotics into your foundry, such as our
Pattern Recognition System Sand Mixer, Omega Sinto can increase production, reduce overall material consumption and improve the consistency and quality of your sand moulds within your foundry.
Our venture into automation doesn’t stop there, as our automated
Pouring and Cooling Lines for moulds are designed to operate at high temperatures, automatically handling molten metals and reducing the risk of accidents within your foundry?.
With over 40 years of industry expertise, we have delivered high-quality foundry equipment to organisations all over the world and continue to hold a market-leading position. Explore our range of
Foundry Equipment here.
3. Focus on Sustainability
Although technological advances are a key driver in reducing energy consumption and energy efficiency (
8), the foundry market is still deemed as a “energy intensive” industry (
9). Our automated systems are therefore designed to reduce waste and energy consumption as much as possible. For example, our sand reclamation plant equipment aims to recover 95% of your used sand for reuse – working as a cost-effective and sustainable solution for
sand foundry operations.
Sustainability is one of the key factors of our business. For more on how Omega Sinto are sustainable, feel free to explore our
Integrated Report (2023) for more information on this.
Related: Omega Sinto’s Role in the Automation Revolution
Omega Sinto’s Final Thoughts on Automation within the Foundry Industry:
Foundry automation, driven by the technological advancements of Industry 4.0, is transforming the foundry industry into a more efficient, safer, and productive sector. By integrating robotics, AI, and smart systems into their operations, modern foundries can enhance productivity, improve product quality, and reduce operational costs.
As the foundry sector continues to evolve, it is clear that automation will remain a cornerstone of progress. Omega Sinto is playing a crucial role in this transformation, leading the charge in making foundries smarter and more sustainable for the industry and overarching markets.
If you have any further questions regarding our position with automation or wish to enquire for one our products, please contact our team to discuss your unique requirements; we're accessible via phone at
+44 (0) 1733 232231, email at
[email protected], or via our
online contact form. We'd love to work with you!
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