The Power of Green Sand: Unlocking Efficiency and Cost Savings for Foundries
Green Sand Technology: A Game-Changer for Foundries
Established by foundry technology experts DISA, the test facility will run production trials for new and existing castings to physically prove the green sand process meets both casting specifications and cost expectations. The test facility will also aid foundries producing iron castings.
The benefits of green sand technology are numerous, and DISA president Ulla Hartvig Tønnesen is keen to highlight the potential for cost savings and efficiency gains. “We want to challenge the industry mindset that certain castings must be made with certain technologies,” she says. “DISA invented high-efficiency, high-quality vertical moulding and perfected it for 60 years. We’re seeing more foundries investigate green sand for aluminum, steel, brass and bronze applications, and this facility will give them the confidence to move ahead with production in green sand.”
The test foundry conducts intensive, end-to-end process development using its complete green sand line. That includes melting, sand mixing, vertical moulding and core shooting, plus metal chemistry analysis and MAGMASOFT simulation for gating and feeding design. Foundries can also submit sand samples to test Simpson sand reclamation and find out what percentage can be reused.
One of the key benefits of green sand technology is the potential for significant cost savings. “We typically see a 15% lower cost per casting by switching to green sand, but it can be 20% or more,” says Ulla. “It’s a big opportunity for non-iron foundries currently using processes like shell, no bake and die casting.”
Ultra-flexible machines like the DISA MATCH and DISAMATIC are already widely used in short-run aluminum, brass and bronze applications. The test foundry will focus on a different alloy every few months, with regular updates via the DISA LinkedIn channel. The facility has already proved to one major US foundry that a DISAMATIC D3 vertical moulding line is perfect for its brass castings.
Why Green Sand Gives You an Edge
Currently working with steel castings, the test foundry will focus on a different alloy every few months, with regular updates via the DISA LinkedIn channel. In a highly competitive global market, moving to green sand for non-iron parts gives foundries the edge they need,” says Ulla. “We – and the DISA test foundry – are here to make it happen.”
Green sand technology offers a number of benefits for foundries, including improved efficiency, reduced costs and increased flexibility. By partnering with DISA, foundries can unlock the full potential of green sand and gain a competitive edge in the market.
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, with a North American facility based in LaGrange, Georgia, 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 that support the whole digital journey from data collection to AI-driven casting quality optimization.