An ISO:9000 Company
Pouring Iron on Six Automatic Molding Centers
PEOPLE
- 250 Employees
- Professional Management Team
- Highly Skilled and Qualified Technical Staff
- Productive, Motivated Craftspeople
FACILITY FEATURES
- 225,000 square feet of manufacturing space all reconstructed in the past 30 years with high bays, insulated roofs and modern lighting
- Discovery Center
- Training Facilities
- Multiple Conference Rooms
- 200 acres of land
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
METALS CAST
Gray Iron
Class 25,30,35,40 tensile and heat resistant ironsSpecifications
- Gray Iron Specifications
- Heat Resistant Iron Specifications
- ISO 9000 Certification
- Pressure Equipment Directive Certification
Ductile Iron
Grades 60-40-18, 65-45-12, 80-55-06, 100-70-03 & 120-90-02Specifications
Austempered Ductile Iron
Grades 110-70-11, 130-90-09, 150-110-07, 175-125-04, 200-155-02 & 230-185-01Specifications
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
PATTERN MAKING
- Complete pattern layout and design with many up-to-date pattern shops at our disposal
- Solid Works
- Magmasoft solidification software
Core Production on Laempe LB25
Core Assembly Area
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
- 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
- Extended cooling lines available to accommodate heavy section jobs
DISA 28×32 Molding Machine
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
- Customized Energy Solutions energy management software with Demand Control and Demand Response features on the furnaces
- Emergency Load Response Program and Synchronous Reserve Program participant to reduce stress on the PJM grid
Tapping Iron from 10 metric ton furnace
FINISHING
- One 14 cubic foot Wheelabrator
- One 28 cubic foot Wheelabrator
- One Wheelabrator spinner hanger
- Six Foxall robotic grinders
- Eight Fox stationary grinders
- Two floor grinding stations
- Empire Performer Blast Unit (for shot blasting small internal passageways, such as hydraulic bodies)
One of Six Robotic Grinding Cells
LAB
- Microscope with Automatic Image Analysis software
- Coordinate Measuring Machine
- Romer 3D Scanner
- Bore scope
- Spectrometer
- Leco Carbon/Sulfur Determinator
- Leco Oxygen/Nitrogen 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
Benton Foundry is constantly modernizing and expanding. This expansion will mean added capacity and increased services to our customers.
