Gemco Engineers B.V. - Engineers & Contractors

PRO

JECTS

A selection of Gemco foundry projects, in brief

Country: MexicoProduct: brake discs and drumsMetal: cast iron

Rassini Frenos SA de CV, manufacturer of brake discs and drums for OEM andspare parts, is one of the biggest and most important plants in reference to vertical molding and not only in casting but also machining its own products. Supply of several production lines. The installation in 2000 comprised a completeproduction line around two vertical moulding machines.

Country: HungaryProduct: exhaust manifolds, turbo-housingsMetal: ductile iron

Concept engineering, project management, detail engineering and supervision ofthe installation of a complete Greenfield foundry for exhaust systems.

Turnkey Sand Preparation Plant, design and supply of a 200 tons/hr green sandsystem with two vacuum cooling mixers.

Country: GermanyProduct: brake discsMetal: grey iron

Concept engineering, project management, engineering and supervision of the installation of building and equipment for a Greenfield foundry.

Country: UK Product: brake discs and drumsMetal: grey iron

Ford Leamington UK: Concept engineering and turnkey realization of a vertical moulding line with sand plant, medium frequency melting furnace complete with charging system, metal transfer and pouring furnace.

Country: Russian FederationProduct: excavator partsMetal: steel

Design, manufacturing, installation and commissioning of a No Bake moulding line and sand regeneration plant.

Country: MexicoProduct: cylinder liners for combustion enginesMetal: grey cast iron

Turnkey realization of a complete foundry for the production of engine cylinder liners, including new melt plant and auxiliary systems.

Country: ChinaProduct: pipe fittingsMetal: ductile cast iron

Turnkey engineering and contracting of sand plant and other process equipmentspecially designed for Saint Gobain PAM moulding equipment. Transfer, re-erection and commissioning of specific equipment from the UK to China.

Country: GermanyProduct: automotive partsMetal: aluminium

Turnkey Lost Foam foundry, design and supply of a complete auto-matic moulding line for 40 flaks per hour. The project comprisedlost foam technology, foundry design, engineering, supply of allequipment, installation and commissioning of the completely auto-mated foundry.

Country: PolandProduct: brake discsMetal: cast iron

Turnkey project that encompassed: Concept engineering, site preparation, foundations, buildings, offices and all utilities. Complete foundry equipment with maintenance shop, laboratories, tooling repair and storage. Training and ramp-up services.

Country: FranceProduct: heating componentsMetal: ductile iron

Concept engineering, turnkey realizationupgrade and automation of the “end ofthe line C4”.

Country: South AfricaProduct: cylinder blocks and –headsMetal: grey iron

Foundry expansion: concept engineering and project management for the mould-ing- and core-shop, shakeout, and casting cooling facilities. Turnkey supply ofgreensand and coresand plants.

BAXI France

Theuns Wessels: “The first pour, inJanuary of this year, marked the end ofa hectic one and a half year and we cannow fully concentrate on productionagain. Gemco provided good supportwith the execution of the master planand actual realization of the project.Their overall involvement and collabora-tion also in those parts of the projectthat were within our own scope of activities, such as civil works, enabledus to ensure continuation of production”

Bas van Gemert(Gemco) and TheunsWessels (Project manager Atlantis) duringthe official opening.

Country: IranProduct: automotive partsMetal: ductile/grey iron

Asia Pearlite Casting Industries Co. Concept engineering, site managementand overall project management for the realization of a Greenfield foundry.

Country: SwedenProduct: tools and diesMetal: grey/ductile iron, steel

Engineering, equipment selection, site management and overall project manage-ment of the Hästveda foundry expansion in order to meet the Camito-methodspecifications.

Conventional pressing/cutting-tools for the automotive industry aremade of special tool-steel sections that are mounted on a cast-ironbase, a highly labour intensive and time consuming activity. With thepatented Camito process the tool steel section can be casted togetherwith the cast-iron base in 1 cast, thus reducing the lead-time. The picture shows a pressing tool manufactured according the Camitoprocess. It shows that the actual pressing part is a single piece that isdirectly cast onto the cast-iron base, rather than a conventional toolassembled from multiple sections.

Gemco Engineers B.V.Engineers & ContractorsScience Park Eindhoven

P.O. Box 17135602 BS Eindhoven

The NetherlandsTel. : +31 40 264 36 43Fax : +31 40 264 36 40e-mail: eng@gemco.nl

Gemco Foundry Technology deMéxico, S.A. de C.V.

13 Sur 1901 Col. Santiago Puebla, México

Tel: + 52 (222) 212 7221 Fax: + 52 (222) 403 3545

E-mail: gemco@gemtel.com.mx

GEMCO International BV ul. Dostoevskogo 21

103030 MOSCOW Russian Federation

Tel: + 7 495 755 5713 Fax: + 7 495 755 6974

E-mail: e.zalevskaya@gemco-international.ru

Knight Wendling GmbH*Cast Metals

Consultants & EngineersKieshecker Weg 240

D-40468 Düsseldorf, GermanyTel.: +49 (0)211-77 00 6-0

Fax: +49 (0)211-77 00 6-77e-mail: info@knightwendling.de

*a Gemco company

www.gemco.nl

Country: ThailandProduct: castings and grinding media for the mining and cementindustry. Metal: high chromium

Magotteaux International SA is located in Vaux sous Chevremont, Belgium,the company is specialized namely in the production of castings and grindingmedia for the mining and cement industry and other applications. Magotteauxdesigns and manufactures wear resistant products to neutralize the variousconstraints encountered in all mill types and to improve the grinding process asa whole. The company considers R&D to be of paramount importance in theirbusiness philosophy and continuously invests in the study and design of thevarious castings required in crushing and grinding equipments Magotteaux has17 foundry plants in operations worldwide.

Cooperation with Magotteaux comprises: implementation of a concept engi-neering report, including the formation of the required budget, for the estab-lishment of a Greenfield foundry for grinding media in Thailand. The projectincludes the design of the overall lay out of the site and the connection to theexisting foundry, the engineering of specified equipment for the new Greenfieldfoundry in Thailand and the project management services for the implementa-tion of this equipment. Further specified project management services to theproject management team during the full realization period of this project.

Country: RussiaProduct: automotive partsMetal: cast iron, carbon steel, aluminium

Concept engineering and project management for the construction of a newjobbing foundry for heavy-duty cast iron, plain carbon steel and aluminiumcastings.

A complete and up-to-date reference list can be viewed on our website.Do not hesitate to contact Gemco if you wish to receive more information.