Why choose Benton Foundry for your iron castings work?  For starters, our facility is equipped with the latest foundry technology to ensure that our castings are produced with unrivaled quality, faster turnaround and lower total cost.  Our continual capital investment program enables us to handle your orders of 50 molds with the same speed and accuracy as your 2500 mold order.  Production is optimized every step of the way – converting jobs to automatic core and molding machines, adding impressions to the tooling, eliminating unnecessary cores, or just making the jobs more “foundry-friendly”. 

In fact, our commitment to innovation, service and quality has been recognized by several leading industry publications.  So, whether it’s our computerized production control system, state-of-the-art spectrographic and metallographic lab, modern electric induction furnaces, reliable trucking fleet or our highly-trained, long-term, technical and customer service staff, you can be sure Benton Foundry has both the equipment and the people to handle your job the way you expect it to be handled.

People

• 250 Employees
• Professional Management Team
• Highly Skilled and Qualified Technical Staff
• Productive, Motivated Craftsmen

Facility Features

• 225,000 Square Feet
• Private Offices
• Conference Rooms
• Training Center

Production Capability

• Medium and high production capacity in casting sizes from 1 to 250 pounds
• Capacity of 30,000 tons per year of finished castings
• Reliable physical properties and consistent microstructure
• Complete pattern layout and design capability

Scheduling

• Computer integrated throughout the casting process
• Centralized, accountable and easily accessible
• Average 97% on time when measured against the customers’ delivery window
• Customized software – Our software fits our process

Core Production Department

• Cold box, shell and no-bake processes
• Two Gaylord 24-VSTB
• Two Gaylord 19-VSTB
• One Gaylord SATB-15
• One Laempe LB25
• Four Beardsley & Piper SF 6
• Two Beardsley & Piper 104
• One Palmer continuous mixer
• Intricate core assembly capability
• Digital images with computerized detailed instructions for all assemblies

Molding Department

• Automated Sand Preparation with two B&P 100B-250 muller’s with Hartley Controls           
• One DISA 28 x 32 flask with a 14” cope and 12” drag adjustable down to an 11” cope and 9” drag
• Two DISA Match 130, 20 x 24 flask with an 8” cope and 8” drag adjustable down to a 6” cope and 6” drag
• One Hunter 20 x 24 flask with an 8.5” cope and 7.5” drag
• Two Hunter 14 x 19 flask with an 5.5” cope and 4.5” drag
• Two Osborne rotolifts (3161 and 3191) for flask sizes up to 30 x 32 with up to a 12” cope and 12” drag
• One squeezer
• One side floor with up to a 30 x 32 flask

Melting Department

• Two 10 metric ton medium frequency Inductotherm furnaces with a 7,000KW power pack and Meltminder controls
• Two 4 metric ton medium frequency Inductotherm furnaces with a 2,500KW power pack and Meltminder controls
• Tight chemistry control with complete traceability
• Excellent, documented temperature control
• 300-Ton-Per-Day melt capacity
• Powerit energy management software with Demand Control and Demand Response features on the furnaces
• Enernoc Emergency Load Response Program and Synchronous Reserve Program participant to reduce stress on the PJM grid

Finishing

• One 14 cubic foot Wheelabrator
• One 28 cubic foot Wheelabrator
• One Wheelabrator spinner hanger
• One Foxall robotic grinder
• Eight Fox stationary grinders
• Eight floor grinding stations

Lab

• Microscope with Automatic Image Analysis software
• Coordinate Measuring Machine
• Bore scope
• Spectrometer
• Leco Carbon/Sulfur Determinator
• PPAP’s
• Chemical certification
• Physical certification
• Metallographic reports
• Letter of Compliance
• Complete, electronic sand lab
• Computerized, customized and completely integrated scrap reporting
• Newage automatic hardness testing machine