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Ductile and Gray Iron Foundry - Metalfit Inc. Metalfit Presentation 2.pdf · Products (Alloys &...

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Ductile and Gray Iron Foundry Commited to Continuous Customer Satisfaction
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Page 1: Ductile and Gray Iron Foundry - Metalfit Inc. Metalfit Presentation 2.pdf · Products (Alloys & Sizes) - Gray Iron ASTM A48 – Class 20, 30 and 40 - Gray Iron ASTM A126 – Class

Ductile and Gray Iron Foundry

“Commited to Continuous Customer Satisfaction”

Page 2: Ductile and Gray Iron Foundry - Metalfit Inc. Metalfit Presentation 2.pdf · Products (Alloys & Sizes) - Gray Iron ASTM A48 – Class 20, 30 and 40 - Gray Iron ASTM A126 – Class

Our Company:

Metalfit was established in Monterrey, Mexico in 1990 as a manufacturer offlanged pipe fittings for distribution to both the U.S. and Canadian markets.Much of the original tooling was purchased from Kuhn's, Inc. in Dayton, OH.Initially the company relied on outside foundries to supply its castingrequirements. It soon became apparent however that in order to offer the highlevel of service Metalfit wanted to achieve we would need our own foundry.Since the principals of Metalfit all had strong foundry backgrounds it only madesense to vertically integrate into the foundry business.

In 1995 we purchased a small cupola gray iron foundry in a suburb of Monterrey which is Pesqueria. The site is now approximately 9.2 Acres and has been under constant growth and development since our acquisition.

We produced our first induction melt ductile iron in April of 1996. In January of2000 Griffin Pipe Products acquired Metalfit and subsequently invested anaddition $3MM in P&E over the next three years. After 3 years and several topmanagement changes Griffin decided to discontinue it's participation in thefittings market with the exception of their large diameter proprietary fittingswhich Metalfit still produces today. The original owners of the company wereoffered the opportunity to buy the business back as Griffin realized its potentialstrategic value to a competitor.

The company currently has approximately has 160,000 square feet under roofand 195 employees.

Page 3: Ductile and Gray Iron Foundry - Metalfit Inc. Metalfit Presentation 2.pdf · Products (Alloys & Sizes) - Gray Iron ASTM A48 – Class 20, 30 and 40 - Gray Iron ASTM A126 – Class

Markets & ProductsWaterworks Residential & Commercial Water

Page 4: Ductile and Gray Iron Foundry - Metalfit Inc. Metalfit Presentation 2.pdf · Products (Alloys & Sizes) - Gray Iron ASTM A48 – Class 20, 30 and 40 - Gray Iron ASTM A126 – Class

Markets & ProductsIndustrial Agricultural

Page 5: Ductile and Gray Iron Foundry - Metalfit Inc. Metalfit Presentation 2.pdf · Products (Alloys & Sizes) - Gray Iron ASTM A48 – Class 20, 30 and 40 - Gray Iron ASTM A126 – Class

Products (Alloys & Sizes)

- Gray Iron ASTM A48 – Class 20, 30 and 40- Gray Iron ASTM A126 – Class A, B, C- Ductile Iron ASTM A536 – Grades 65-45-12, 70-50-05, 80-55-06

- Capability of Pouring:

Min. 5 lbs Max. 2.5 Tons

Page 6: Ductile and Gray Iron Foundry - Metalfit Inc. Metalfit Presentation 2.pdf · Products (Alloys & Sizes) - Gray Iron ASTM A48 – Class 20, 30 and 40 - Gray Iron ASTM A126 – Class

Customers

Page 7: Ductile and Gray Iron Foundry - Metalfit Inc. Metalfit Presentation 2.pdf · Products (Alloys & Sizes) - Gray Iron ASTM A48 – Class 20, 30 and 40 - Gray Iron ASTM A126 – Class

Location:

Property: 9.2 Acres Under Roof: 160,000 Sq. Feet

Address: Carretera a Pesquería Km. 3, Pesquería N. L. México

Page 8: Ductile and Gray Iron Foundry - Metalfit Inc. Metalfit Presentation 2.pdf · Products (Alloys & Sizes) - Gray Iron ASTM A48 – Class 20, 30 and 40 - Gray Iron ASTM A126 – Class

Production Capabilities:

-Tooling Production

-Tooling Storage

-Induction Melting

-Green Sand Molding

-No-Bake Molding

-Floor Molding

-Coremaking

-Cleaning and Grinding

-Machining (Conventional Equipment)

-CNC Machining

-Hydrostatic Testing

-Painting and Lining

Page 9: Ductile and Gray Iron Foundry - Metalfit Inc. Metalfit Presentation 2.pdf · Products (Alloys & Sizes) - Gray Iron ASTM A48 – Class 20, 30 and 40 - Gray Iron ASTM A126 – Class

Tooling Production:

Complete patternshop for theproduction of traditional manualpattern making, as well as with stateof the art computer assisted designand tooling manufacture with CNCequipment. Materials for toolingavailable in wood, resin, andaluminum

Page 10: Ductile and Gray Iron Foundry - Metalfit Inc. Metalfit Presentation 2.pdf · Products (Alloys & Sizes) - Gray Iron ASTM A48 – Class 20, 30 and 40 - Gray Iron ASTM A126 – Class

Tooling Storage:

In our 37,000 square feet toolingwarehouse we store around 3,000different patterns and core boxes

Page 11: Ductile and Gray Iron Foundry - Metalfit Inc. Metalfit Presentation 2.pdf · Products (Alloys & Sizes) - Gray Iron ASTM A48 – Class 20, 30 and 40 - Gray Iron ASTM A126 – Class

Induction Melting:

Inductotherm Furnace Dual Track 1,250 KW

Inductotherm Furnace Power Track 1,250 KW

Combined Melting Capacity: 4.2 Tons/hr.

Page 12: Ductile and Gray Iron Foundry - Metalfit Inc. Metalfit Presentation 2.pdf · Products (Alloys & Sizes) - Gray Iron ASTM A48 – Class 20, 30 and 40 - Gray Iron ASTM A126 – Class

Green Sand Molding:

- Semiautomated molding line flask size 30” x 30” – 12”/12” for castings from 5 to 150 pounds.

- Semiautomated molding line flask size 42”x44” – 16”/16” for castings from 150 to 300 pounds.

Page 13: Ductile and Gray Iron Foundry - Metalfit Inc. Metalfit Presentation 2.pdf · Products (Alloys & Sizes) - Gray Iron ASTM A48 – Class 20, 30 and 40 - Gray Iron ASTM A126 – Class

No Bake Molding:

Semiautomated flaskless moldingline. Molds up to 64”x64” – 24”/24”for castings from 300 to 1,000 pounds

Page 14: Ductile and Gray Iron Foundry - Metalfit Inc. Metalfit Presentation 2.pdf · Products (Alloys & Sizes) - Gray Iron ASTM A48 – Class 20, 30 and 40 - Gray Iron ASTM A126 – Class

Floor Molding:

Floor Molding Flasks up to amaximum of 110”x110” – 45”/45” forcastings from 1,000 to 5,000 pounds

Page 15: Ductile and Gray Iron Foundry - Metalfit Inc. Metalfit Presentation 2.pdf · Products (Alloys & Sizes) - Gray Iron ASTM A48 – Class 20, 30 and 40 - Gray Iron ASTM A126 – Class

Coremaking:

Shell and No-Bake Coremaking

Page 16: Ductile and Gray Iron Foundry - Metalfit Inc. Metalfit Presentation 2.pdf · Products (Alloys & Sizes) - Gray Iron ASTM A48 – Class 20, 30 and 40 - Gray Iron ASTM A126 – Class

Cleaning and grinding:

1 Wheelabrator Turntable Blast Machine

2 Pangborn Tumbleblast Machines

Page 17: Ductile and Gray Iron Foundry - Metalfit Inc. Metalfit Presentation 2.pdf · Products (Alloys & Sizes) - Gray Iron ASTM A48 – Class 20, 30 and 40 - Gray Iron ASTM A126 – Class

Machining (Conventional Equipment)

13 Conventional Machine Tools: 1 Horizontal Boring Mill1 Horizontal Lathe3 Vertical Lathes 2 Boreface Machines,4 Multiple Spindle Drills 2 Radial Arm Drills

Page 18: Ductile and Gray Iron Foundry - Metalfit Inc. Metalfit Presentation 2.pdf · Products (Alloys & Sizes) - Gray Iron ASTM A48 – Class 20, 30 and 40 - Gray Iron ASTM A126 – Class

CNC Machining:

7 CNC Machines: 1 Horizontal Lathe 2 Vertical Turret Lathes 2 Vertical Machining Centers 2 Horizontal Machining Centers

Page 19: Ductile and Gray Iron Foundry - Metalfit Inc. Metalfit Presentation 2.pdf · Products (Alloys & Sizes) - Gray Iron ASTM A48 – Class 20, 30 and 40 - Gray Iron ASTM A126 – Class

Hydrostatic testing:

Hydrostatic testing for partsthat service under pressure.

Page 20: Ductile and Gray Iron Foundry - Metalfit Inc. Metalfit Presentation 2.pdf · Products (Alloys & Sizes) - Gray Iron ASTM A48 – Class 20, 30 and 40 - Gray Iron ASTM A126 – Class

Painting and Lining:

Coatings and linings applied bybrushing, spraying or dipping.

Page 21: Ductile and Gray Iron Foundry - Metalfit Inc. Metalfit Presentation 2.pdf · Products (Alloys & Sizes) - Gray Iron ASTM A48 – Class 20, 30 and 40 - Gray Iron ASTM A126 – Class

Quality Control:

Our Quality Control System provides the framework to ensure quality throughout our process. Our laboratory is fully equipped for:

- Sand testing

- Chemical analysis (Spectrometer and Leco)

- Mechanical testing (Universal Machine, Brinnell hardness)

- Metalographic Analysis

- Ultrasonic Testing

- Dimensional Lay-out and Inspection

We will be certified ISO-9001:2008 by the end of 2011.

Page 22: Ductile and Gray Iron Foundry - Metalfit Inc. Metalfit Presentation 2.pdf · Products (Alloys & Sizes) - Gray Iron ASTM A48 – Class 20, 30 and 40 - Gray Iron ASTM A126 – Class

Quality Control:

We offer 100% traceability of our products

Page 23: Ductile and Gray Iron Foundry - Metalfit Inc. Metalfit Presentation 2.pdf · Products (Alloys & Sizes) - Gray Iron ASTM A48 – Class 20, 30 and 40 - Gray Iron ASTM A126 – Class

Storage of Finished Product:

Inventory of finished product toprovide the best possible serviceto our customers

Page 24: Ductile and Gray Iron Foundry - Metalfit Inc. Metalfit Presentation 2.pdf · Products (Alloys & Sizes) - Gray Iron ASTM A48 – Class 20, 30 and 40 - Gray Iron ASTM A126 – Class

List of Equipment:Qty Description

TOOLING PRODUCTION1 Quintax CNC Router 5-axis with computer assisted design capabilities.

MELTING2 Inductotherm Melting Units, 1250 Kw, with 2 Coreless Furnaces 1.5 Ton ea.

GREEN SAND PREPARATION1 Beardsley & Piper 85-B Speed-muller, 3000 Lb. batch.1 National Engineering Mulller 2 ½ F, 2600 Lb. batch.1 Full Installation for handling, storage and preparation of the returned sand.

GREEN SAND MOLDING1 Semi-automatic Cope and Drag Molding Line, flask size 30"X30"- 12"/12“ with

International PVKL jolt-squeeze molding machines and complete mold handling system.1 Semi-automatic Cope and Drag Molding Line, flask size 42"X44"- 16"/16“ with

International PVKL jolt-squeeze molding machines and complete mold handling system.NO-BAKE SAND PREPARATION

1 Palmer Mechanical Sand Reclaimer, 10 Tons/hour1 Gudgeon Thermal Reclaimer, 1 Ton/hour

NO-BAKE MOLDING LINE1 Palmer Continuous mixer M1000XL, 1000 pounds per min1 Semiautomatic Molding Line with vibration table, mold handler, rollover, belt conveyor

and hydraulic mold pushers.3 5 Tons Overhead Bridge Cranes

NO-BAKE FLOOR MOLDING LINE1 Palmer Continuous mixer M1000XL, 1000 pounds per min3 15 Ton Overhead Bridge Cranes

COREMAKING1 Shalco U-360 Shell-Core Machine, 200 pound max core 1 B&P Cormatic SF-10A Shell-Core Machine, 100 pound 1 Carver Continuous mixer, 300 pounds per min - No Bake sand1 Dependable Continuous mixer, 500 pound per min - No Bake sand

CLEANING & GRINDING2 Pangborn 34N Rotoblast machines, 34 cubic foot capacity.1 Wheelabrator shot blast machine. Swing Table type, 96” Table3 Hermann Williams Bottom-up drills.

Page 25: Ductile and Gray Iron Foundry - Metalfit Inc. Metalfit Presentation 2.pdf · Products (Alloys & Sizes) - Gray Iron ASTM A48 – Class 20, 30 and 40 - Gray Iron ASTM A126 – Class

List of Equipment:Qty Description

MACHINING-CONVENTIONAL EQUIPMENT1 Union BTF 110 Horizontal Boring Mill, 5" Spindle with CNC Control 1 Bullard Cut Master M-75 Vertical Boring Mill Table 66" Swing 78"1 Gidding & Lewis 64-VBM Vertical Boring Mill Table 62", Swing 64"1 King Vertical Boring Mill, Table 42", Swing 46"1 Monarch Horizontal Engine Lathe, Swing 26"1 Natco B20B Two Way Head Borefacing machine1 Natco B20B Three Way Head Borefacing machine1 Natco Multiple Spindle Drill Press B3A - 12 Spindle, 1.5" Upper2 Natco Multiple Spindle Drill Press D4B - 16 Spindle, 2" Upper1 Natco Multiple Spindle Drill Press G4E - 36 Spindle, 1.5 Upper1 Carlton Radial Arm Drill 15" Col, 5 Feet Arm1 Carlton Radial Arm Drill, 9" Col, 4 Ft Arm

CNC MACHINING1 Toyoda FH-100 CNC Horizontal Machining Center 1 Mori-Seiki MH 63 CNC Horizontal Machining Center 1 Monarch VMC 45 CNC Vertical Machining Center 1 Mori-Seiki MV 65 CNC Vertical Machining Center 1 Olympia V-40 CNC Vertical Turret Lathe, Table 46", Swing 57" 1 Gidding & Lewis 60VTL CNC Vertical Turret Lathe, Table 60", Swing 70"1 Mori-Seiki SL-7 "Slant Bed" CNC Lathe, Swing 24"

PAINTING1 Chain conveyor for dip painting.1 Booth for spray painting.

LABORATORY

1 Complete sand control equipment: moisture teller, permeameter, sand strength tester, methylene blue, grain fines rotap, shell and pep-set strength testers

1 Spectrometer Spectro-cast for 18 elements.1 Leco Carbon Determinator1 Ledds & Northtrup Quick-lab for carbon/silicon indicator.1 Unitron Microscope for metalographic analysis.2 Brinnel hardness testers.1 Ultrasonic Tester for nodularity and wall thickness.1 Tensile Test Machine Tinus Olsen, 30 T

Page 26: Ductile and Gray Iron Foundry - Metalfit Inc. Metalfit Presentation 2.pdf · Products (Alloys & Sizes) - Gray Iron ASTM A48 – Class 20, 30 and 40 - Gray Iron ASTM A126 – Class

Profile of the owners:

Manuel Ruiz: President Mark Meyer : Vice President

Bruce Eilenberger: Director Ted Muntz: Director

Mechanical Engineering Monterrey Institute of Technology MS Metallurgy National University of Mexico MBA Monterrey Institute of Technology Industrial Engineer, Fundidora Monterrey Production Control, Fundiciones Ruiz (Fittings Foundry) Plant Manager, Fundiciones Ruiz President, Fundiciones Ruiz

General Motors Institute BS Mechanical Engineering/Metallurgy MS Mechanical Engineering/Metallurgy MBA Northeastern University Research Engineer, General Motors Superintendent of Production General Motors Foundry Manager, Ward Manufacturing President, Ward Manufacturing President, Tokheim, Inc. NYSE Corporate turn-around consultant, various

assignments

Regis University George Mason University 2 years Active Duty U.S. Army. Regional Manager Gustin Bacon Div. of Aeroquip Corp. Regional Manager ITT Grinnell National Sales Manager Ward Manufacturing Chief Marketing Officer Ward Manufacturing President Ward Manufacturing

B.A. University of Iowa Territory Manager A.Y. McDonald Mfg. CO. National Sales Manager Pump Div. A.Y. McDonald Mfg. Co. National Sales Manager Manuf. Div. A.Y. McDonald Mfg.Co. President – Fab Pipe Inc. Standards Council Chair for National Association of Pipe

Fabricators Past President – National Association of Pipe Fabricators ANSI/AWWA A21 Committee Member 35 Years Concentrated Waterworks Industry Experience


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