MANUFACTURING PROCESSES

OVERVIEW

1

INDEX

GLASSMELTING

4

8

12

16

20

24

6

10

14

18

22

NODULARIRON CASTING

NON-FERROUSMELTING DIE CASTING

CONTINUOUSCASTING

CERAMICMOLD CASTING

PLASTICINJECTION MOLDING

PERMANENTMOLDING

ROTATIONALMOLDING

ASSEMBLYOF PRODUCTS

GALVANIZING

2

3

ww

w.iu

sa.m

x GLASSMELTING

4

GEN

ERA

L C

ATA

LOG

MA

NU

FAC

TUR

ING

PR

OC

ESSE

S

Formulas are prepared according to the master list of components added for each type of piece. Each element is weighed in a scale with a dust collector, and is then transferred to a hopper. Secondary components are added to the main elements in the hopper to complete the formula.

1 PREPARATION OF MIXTURES

PROCESS

2INTRODUCING RAW MATERIALS INTOTHE FURNACE

The formula in the hopper and dust collector is continuously fed into the surface of the furnace through a distribution arm in order to full fuse the glass into a uniform layer.

3 GLASS MELTING

Glass undergoes a 5-step melting process in a fully-electric furnace as follows: • Melting tank• Fining tank• Throat• Elevator• Sandblasting unit (the glass temperature is controlled by the combustion of gas and air in order to give the glass the proper volume, shape and weight depending on the piece to be manufactured).

Soluble oil is used to cool and lubricate the drop-cutting blades. A closed-circuit water cooling system is integrated into the furnace.

4 GLASS PRESSING

Glass drops are formed into gobs with the specifications of the piece to be shaped. Then, a 12-position hydraulic press, steel molds and a core piston are used to shape the glass. Molds are continuously lubricated with oil through rubber rolls.

5 HOMOGENIZATION TANK

At this stage, glass is transferred from the press to the furnace to apply heat homogeneously at a temperature of 615 °C. Natural gas is used in order to temper glass better.

8 SELECTION OF FINISHED PRODUCT

Every piece in the manufactured batch undergoes quantitative and qualitative inspection to eliminate the gobs that do not meet the physical requirements outlined in our procedures and operation guidelines. Pieces may be discarded if they are:• Incomplete• Cracked• Scratched (with bright superficial lines)

6 GLASS TEMPERING

The glass gob comes out of the press at an approximate temperature of 800°C. The gob goes through a train of natural gas burners and air for the piece to have a homogeneous temperature of 750 °C. Then, the gob goes into a carousel where air is injected at a different volume and temperature to abruptly decrease the material temperature to approximately 200 °C.

7 TEST LINEThe tempered glass gob is carried through natural gas modules by a metal conveyor as to test the resistance of the glass to thermal shock. Thermal resistance tests are divided as follows:• POSITIVE: the glass piece is moved from an area at room temperature to an enclosure at 380°C• NEGATIVE: the glass piece is heated up to approximately 140°C and then placed inside a water container at 20 °C. This container has a closed-circuit cooling system.

9 PACKAGING

During packaging, the full batch undergoes inspection, and is then placed inside its package to be sent to the point of assembly or shipped as a finished piece.

FEATURES AND ADVANTAGES• Automatic weighing system• National raw materials• 100% electric melting system with impurity-removing system • 12-position hydraulic press• Improved tempering process• 18-position annealing lehr with forced air injection • Natural gas combustion system and automatic temperature control • Full batch verification • Release warranty for products held in quarantine • Qualitative and quantitative verification of the finished product

CERTIFICATES• Certified supplier by the testing, equipment and materials laboratory of the federal electricity commission (LAPEM CFE)• ISO 9001-2008

QUALITY CONTROL• Glass gob quality control• Chemical control of raw materials• Melting temperature control in furnace • Gob temperature control • Gob weight control • Temperature control of the homogenization furnace • Tempering cooling control • Temperature control of routine tests • Temperature control of thermal-shock-inducing water • Finished product quality control • Quality control of mechanical resistance tests

5

ww

w.iu

sa.m

x NODULARIRON CASTING

6

GEN

ERA

L C

ATA

LOG

MA

NU

FAC

TUR

ING

PR

OC

ESSE

S

Cores are manufactured using cold box or hot box techniques, as well as a compound mixture of silica and resins. Pneumatic pressure is applied while casting into the desired shape. Then, a catalyst is added to the mold to harden the iron compound. Finally, the mold is removed after the metal has cooled down.

1 FABRICATION OF CORES

PROCESS

2 METAL MELTING

Metal scraps, graphite flakes and ferro-silicon are cast in order to obtain the gray iron alloy requested by the client. Materials are melted by applying heat to a core-free induction melting furnace operating at the frequency of the network.

3 FABRICATION OF MOLDS

At this stage of the process, high-density sand molds are manufactured by pressurized blow molding machines that compress and shape the materials according to the selected pattern plates. The plates are placed opposite from one another to create a two-face mold with vertical injection.

4 METAL TREATMENT PROCESS

Graphite flakes from the cast iron base are turned into nodes (pellets) through the incorporation of a ferrous alloy with magnesium.

5 METAL STRAINING PROCESS

The previously manufactured molds are filled with cast iron, which is then treated according to the desired specifications.

6 FINISHING

The cast iron pieces are thoroughly cleaned from superficial impurities and rough seams.

7 SHIPPING

The cast pieces are shipped according to the delivery schedule and conditions previously agreed on with the client in order for the supplied materials to be available for subsequent manufacturing processes.

FEATURES AND ADVANTAGES• Compliance in size.• Compliance with production standards.• Dual-track melting process.• Automatic molding and coring process .• High-efficiency molding process.• Semi-automatic casting process with timer-controlled straining. • Permanent supervision during manufacturing process. • High-quality warranty.

CERTIFICATES• ISO 9001 2008

QUALITY CONTROLFabrication of cores:• Regulated amount of resins and catalyst. • Controlled curing time and temperature.

Metal melting:• Calculation of loads.• Classification of scraps.• Initial and final chemical control.• Melting temperature control through an immersion pyrometer that regulates the metal volume injected into the line.

Fabrication of molds: • The mold manufacturing equipment operates with the following components and parameters according to the pieces to be cast: • Plates.• Width.• Core.• Pressure.• Speed.• Compressibility.

Metal treatment process:• Magnesium ferrosilicon.• Inoculant amount control.• Metallographic analysis to test materials for compliance with the client’s requirements.

Metal straining process: • Cast temperature.• Cast time.• Number of strained molds.• Final chemical analysis per piece.• Final metallographic structure.

Finishing: • Visual inspection of surface cleanliness.• Separation of defective pieces.

7

ww

w.iu

sa.m

x NON-FERROUSMELTING

8

GEN

ERA

L C

ATA

LOG

MA

NU

FAC

TUR

ING

PR

OC

ESSE

S

Metals (copper, aluminum, tin, etc.) are molten at high temperatures (depending on the melting point) in tilting-type melting furnaces driven by a mix of natural gas and air to obtain the required alloy

1 METAL MELTING

PROCESS

2 FABRICATION OF MOLDS

Molds are manufactured through the CO2 process with a mix of sodium silicate and silica sand. The materials are put in a molding box with the required model plate, and are then pressed in two stages: • Upper• LowerThe molding boxes are removed from the model plate, and pressed together to prevent metal leaks. Once the two halves of the mold are joined, the mold is ready to get the molten metal into the desired shape

3 CASTING

Molten metal is poured into the previously manufactured molds to obtain the desired piece.

4 SHIPPING

Pieces undergo the final steps before being dispatched. Finishing requires 3 steps: • Cutting: the piece is separated from the casting system • Grinding: burrs and rough seams are removed from the piece • Blasting: the surface of the piece is cleaned

5 SHIPPING

The cast pieces are shipped according to the delivery schedule and conditions previously agreed on with the client in order for the supplied materials to be available for subsequent manufacturing processes

FEATURES AND ADVANTAGES• Multiple copper-based and aluminum-based alloys available. • Internal manufacturing of molds.• Easy-to-use machinery.• Full compliance with the client’s specifications.• Full-batch quality control.

CERTIFICATES• ISO 9001:2008

QUALITY CONTROL• Calculation of loads depending on type of alloy.• Final chemical analysis of the alloy.• Pressing pressure.• Resistance to sand.• Casting temperature.• Control of cast molds.• Cast speed.• Metal inlet size measurement.• Measurement of separation between piece and feedline. • Visual inspection of grinding conditions.• Visual inspection of state of cleanliness. • Separation of pieces with superficial flaws.• Quality certificate in every batch.

9

ww

w.iu

sa.m

x DIE CASTING

10

GEN

ERA

L C

ATA

LOG

MA

NU

FAC

TUR

ING

PR

OC

ESSE

S

Aluminum (A380) or Zamac (aluminum, zinc, magnesium and copper alloy) is forced or injected into a permanent mold and placed in a 3-phase cold chamber.

1

PROCESS

2 METAL MELTING

Metal is melted to obtain the alloys requested by the client. Metals are melted in a tilting-type furnace and a combustion furnace at 680 °C until the desired alloy is obtained.

3 VERIFICATION OF ALLOY COMPOSITION

The alloy undergoes chemical verification tests. Gas is removed from the materials, and then the vacuum tests are performed.

4 METAL INJECTION

Once aluminum is melted and heated up to the temperature required by the alloy and the final product, materials are cast into the mold and pressure is applied to obtain the final piece.

5

6

FINISHING

SHIPPING

Pieces are checked for compliance with the required specifications.

The cast pieces are shipped according to the delivery schedule and conditions previously agreed on with the client in order for the supplied materials to be available for subsequent manufacturing processes.

FEATURES AND ADVANTAGES• Being a continuous production process, die casting is a low-cost alternative. • Pieces may be manufactured in different sizes and complex shapes. • Outstanding precision in manufacturing size: +-0.001”• Feasible production of pieces up to 8 kgs.• Secondary operations are unnecessary due to the flawless finishing of the pieces, hence eliminating deburring and blasting. • The final pieces have smooth finishings free of pores. • Permanent supervision during the production process. • High-quality warranty.

CERTIFICATESISO 9001:2008

QUALITY CONTROL• Melting temperature control.• Spectrometry for chemical analysis. • Gas removal to prevent pores and cracks. • Vacuum test tubes to verify absence of pores and cracks. • Size control and verification.

11

ww

w.iu

sa.m

x CONTINUOUSCASTING

12

GEN

ERA

L C

ATA

LOG

MA

NU

FAC

TUR

ING

PR

OC

ESSE

S

Raw materials are checked to verify compatibility with the most commonly produced alloys and/or the client’s specifications in terms of their chemical composition.

1 RECEPTIONOF RAW MATERIALS

PROCESS

2 METAL MELTING

Approved raw materials are melted in electric induction furnaces operating at the rate of the production network. A sample of the molten metal is taken with specially engineered test tubes (polishing one of the faces), and is then sent to the chemical quality lab to be analyzed with optical emission spectroscopy. This analysis detects and registers the % of metal components present in the sample.

3 ALLOY ANALYSIS

The representative sample must be compatible with the expected alloy. Otherwise, the amount of metal components in the furnace is modified, meaning that metals or chemical compounds will be added to meet the required percentages as per ASTM standards. These standards set a reference framework for the quality and composition of the products supplied to our clients.

4 FABRICATION OF INGOTS

Following the approval of the quality department, the molten metal is cast into another induction furnace at a temperature that keeps metal in liquid state according to the requirements necessary for its subsequent casting into ingots. Then, the metal is cast into a mold in a controlled way, either through the furnace or a proportioner.Metal is shaped into ingots through a high-efficiency heat exchanger called mold (temperature is reduced from a range between 1160 °C and 1100 °C to 25 °C).

5 INGOT CUTTING

Ingots are cut with a power saw into the shape necessary according to the requirements of the subsequent extrusion and pressing stages.

6 SHIPPING

The cast pieces are shipped according to the delivery schedule and conditions previously agreed on with the client in order for the supplied materials to be available for subsequent manufacturing processes

FEATURES AND ADVANTAGES

• Backflow is avoided since the void generated due to contraction is immediately filled. • Cross-segregation is reduced, while longitudinal segregation disappears due to the relatively small size of the sections of the ingot. • Continuous casting is easier and quicker since ingots are not placed in preheating furnaces and are not subject to trimming, hence decreasing the operational costs. • Permanent supervision of the production process. • High-quality warranty.

CERTIFICATESISO 9001 2008.

QUALITY CONTROL• Chemical analysis of raw materials, in-process product, and finished product with optical emission spectroscopy and oxygen calculation equipment (tests vary according to type of alloy.) • Control, registration and identification of batches of raw materials, molten metal, finished product, non-compliant product, and rejected product. • Final inspection of individual finished pieces.• Step-by-step process performance measurement.

13

ww

w.iu

sa.m

x CERAMICMOLD CASTING

14

GEN

ERA

L C

ATA

LOG

MA

NU

FAC

TUR

ING

PR

OC

ESSE

S

The powdered paste is mixed according to the required specifications in terms of grain size and raw materials. Once the elements have been mixed, the paste is put in metallic containers to keep proper moisture levels. The same containers will be used in subsequent stages of the process.

1 PREPARATIONOF THE PASTE

2The grained paste is pressed in a metallic container. Pressure is applied to shape the piece according to specifications. Once the piece has been shaped and released from pressure, it is placed on a wooden base and a rack to let it stand.

3 DRYING

The pieces (with 11% moisture content) are place in drying chambers at a temperature of 80 °C to decrease moisture levels to 3%.

4 POLISHING / DEBURRING

The piece is checked for rough edges and excess materials which are then removed.

5 ENAMELING

The piece is placed on a rotary grid at 360 °C and enamel is uniformly applied through aspersion according to specifications.

6 BAKING

The pieces are automatically placed in a roller hearth furnace. Once inside, the pieces undergo 3 baking stages ranging between 75 °C and 1085 °C. • Pre-heating• Sintering• Cooling

7 INSPECTION

Once out of the furnace, the piece is checked for compliance with the established parameters.

8 SHIPPING

The cast pieces are shipped according to the delivery schedule and conditions previously agreed on with the client in order for the supplied materials to be available for subsequent manufacturing processes.

FEATURESAND ADVANTAGES

• Compliance with size requirements• Compliance with production standards• High-efficiency molding time• Automatic sintering• Permanent supervision of production process • High-quality warranty

CERTIFICATES

• Clean industry • ISO 9001-2008

QUALITY CONTROL

• Verified compliance with specifications • Full check to identify cracks • Moisture content control• Full visual check of the finished piece • Enamel density control

PROCESS

15

ww

w.iu

sa.m

x PLASTICINJECTION MOLDING

16

GEN

ERA

L C

ATA

LOG

MA

NU

FAC

TUR

ING

PR

OC

ESSE

S

Virgin resin is loaded into a heater where the material is dried at specific temperatures depending on the type of polymer to eliminate moisture accumulating on the surface due to storage and transportation conditions.

1 DRYING MATERIALS

PROCESS

2 MOLDING OF THE PIECES

• Materials are loaded into the injection machine.• Materials are molten inside the machine.• Materials are injected into the mold.• Materials cool down and take the shape of the mold.• The piece is unmolded

3 INSPECTION

The pieces undergo inspection to ensure full compliance with the specifications agreed on with the client.

4 SHIPPING

The cast pieces are shipped according to the delivery schedule and conditions previously agreed on with the client in order for the supplied materials to be available for subsequent manufacturing processes.

FEATURES AND ADVANTAGES• Quick cycles: 30 - 60 seconds per cycle• Finished product after unmolding• Ensured material uniformity throughout the batch• Continuous process with feasible 24/7 operation • Ideal for big scale production • Highly-versatile process in terms of available shapes and materials: • Noryl™ with fiberglass (PPO) • Acrylonitrile butadiene styrene (ABS) • Polycarbonate (PC) • High-density polyethylene (HDPE)• Polypropylene (PP)• Low-density polyethylene (LDPE)• Polyoxymethylene (POM)• Polyvinyl chloride (PVC)

CERTIFICATESISO 9000:2008ANCE

QUALITY CONTROL• Standard operation procedures • Hourly production registry • On-site inspection at the machine• Fabrication and maintenance of molds: • Computer numeric control (CNC)• Penetration machines (electrical discharge machining)• Jig grinder• Stereolithography equipment for resin prototypes • Thermal treatment equipment

17

ww

w.iu

sa.m

x PERMANENTMOLDING

18

GEN

ERA

L C

ATA

LOG

MA

NU

FAC

TUR

ING

PR

OC

ESSE

S

Copper, aluminum and recirculated metal scraps are molten in a core-free induction furnace in order to obtain a bronze-aluminum alloy

1 FUSION

PROCESS

2 MOLDING

The copper-beryllium molds are automatically filled to cast the desired pieces

3 FINISHING

Pieces are given their final appearance by cutting, sanding and deburring metal seams

4 SHIPPING

The cast pieces are shipped according to the delivery schedule and conditions previously agreed on with the client in order for the supplied materials to be available for subsequent manufacturing processes.

FEATURES AND ADVANTAGES• Fusion is controlled in each furnace through a potentiometer.• Permanent molding allows more precise casting of all the pieces.• Automatic process.• Time-efficient process.• Improved cost-reduction.• Permanent supervision of the production process. • Quality warranty of the cast product.

CERTIFICATES• N/A

QUALITY CONTROL• Chemical analysis.• Temperature control during injection into molds. • Dimensional analysis of molds and pieces.• PLC-controlled movement.• Dimensional analysis of each piece.• Visual inspection and separation of defective cast pieces. • Batch arrangement and verification.

19

ww

w.iu

sa.m

x ROTATIONALMOLDING

20

GEN

ERA

L C

ATA

LOG

MA

NU

FAC

TUR

ING

PR

OC

ESSE

S

A powdered polymer is poured inside the mold. Then, the mold is hermetically sealed. The amount of polymer must be calculated according to the size of the piece to be manufactured

1

PROCESS

2The closed mold is placed in a furnace at a temperature ranging between 300 and 350 °C where the polymer will melt or sinter. The mold begins to rotate slowly around two perpendicular axes placed across the center or gravity of the piece. Rotary motion makes the polymer cover the internal walls of the mold in a relatively uniform war, hence creating a hollow piece

3Finally, the mold is left to cool down, and the solid piece is unmolded

4 FINISHING

During the last stage of the process, the rotomolded piece is trimmed, cleaned and finished for use

5 SHIPPING

The rotomolded pieces are shipped according to the delivery schedule and conditions previously agreed on with the client in order for the supplied materials to be available for subsequent manufacturing processes

FEATURES AND ADVANTAGES• Strict compliance with size requirements.• Strict compliance with production standards. • Pieces may be manufactured in different sizes and complex shapes thanks to a versatile production process. • Customizable wall thickness to meet the client’s requirements.• Pieces may be manufactured in different customizable colors.• Permanent supervision of the production process. • High-quality warranty.

CERTIFICATES• ISO 9001:2008

QUALITY CONTROL• Volume capacity control.• Measurement of sun ray filtration. • Torque control in lid.• Inspection of sediment beds.• Wall thickness control.

21

ww

w.iu

sa.m

x ASSEMBLYOF PRODUCTS

22

GEN

ERA

L C

ATA

LOG

MA

NU

FAC

TUR

ING

PR

OC

ESSE

S

Several assembly parts of different products are manufactured with multiple raw materials such as copper, brass, steel, stainless steel, and aluminum.

1 DIE-CUTTING

PROCESS

2 BRIGHT FINISHING

If required, a bright finish is given to the die-cut assembly parts of the final product.

3 BOLTING

A great variety of screws is manufactured to be subsequently mounted on other products. Bolts, nuts, and screws are made of a copper-iron alloy with a special weather-resistant finish.

4 ASSEMBLY

The different parts (internally or externally manufactured) are assembled in workshops by qualified staff who use the necessary tools according to the requirements of the final product.

5 SHIPPING

The pieces are shipped according to the delivery schedule and conditions previously agreed on with the client in order for the supplied materials to be available for subsequent manufacturing processes.

FEATURES AND ADVANTAGES• Compliance with size requirements.• Qualified staff.• Proper tools and work areas according to the process in question.• Ensured compliance with production standards. • Permanent supervision during production stages.• High-quality warranty.

CERTIFICATESISO 9001:2008.

QUALITY CONTROLDie-casting• Size measurement of every piece.

Bright finishing• Amount of chemicals.• Time and temperature.

Bolting• Size measurement of every piece.

Assembly• Visual inspection.• Separation of defective pieces.• Performance of acceptance tests.• Application of delivery protocols.

Shipping• Visual inspection.• Application of delivery protocols.ASSEMBLY

OF PRODUCTS

23

ww

w.iu

sa.m

x GALVANIZING

24

GEN

ERA

L C

ATA

LOG

MA

NU

FAC

TUR

ING

PR

OC

ESSE

S

Iron-based pieces are received and inspected before being prepared for pickling

1 MATERIAL RECEPTION

PROCESS

2 PICKLING

The pieces are degreased, washed, pickled and rinsed to remove impurities and soften their surface

3 FLUXING

The pieces are immersed in an aqueous solution with zinc and ammonium salts at a specific temperature in order to facilitate the diffusion of zinc in the base metal of the pieces

4 GALVANIZING

The pieces are immersed in molten zinc to create a corrosion-resistant layer of zinc and iron around the pieces

5 FINAL INSPECTION

The quality of the zinc coating is verified through visual inspection and physical tests.

7 SHIPPING

The cast pieces are shipped according to the delivery schedule and conditions previously agreed on with the client in order for the supplied materials to be available for subsequent manufacturing processes.

6 FINISHING

The metal pieces are finished in order to remove superficial rough seams or scraps

FEATURES AND ADVANTAGES• Multiple sizes available• Galvanizing of steel-made and cast pieces • Variable speed according to requirements • Flexible zinc-immersion time • Manual and semi-automatic process• Continuous process improvement to increase productivity

CERTIFICATESISO 9001 2008

QUALITY CONTROL• Acid concentration control• Fluxing concentration control• Molten zinc temperature control• Immersion time control• Verification of unit sizes• Verification of coating thickness of each piece

WORLDWIDE SALES:

SUPPLY CONCEPTS, NORTH AMERICA 46 West. Jefryn Blvd Deer Park, N.Y. 11729 Phone (631) 661-6915 Fax (631) 321-5662

SUPPLY CONCEPTS, MEXICO Volcán Fujiyama 1997 El Colli Urbano Zapopan Jalisco Mexico CP 45070 Phone (52) 33- 2410 1201 Fax (52) 33 3770-2300

SUPPLY CONCEPTS, EUROPE B.S.R Tower 1, floor 11, Ben Gurion St. 2 Ramat Gan 52573, Israel Phone 972732424530 Fax 972 3 941 5636

www.supplyww.com ○ www.iusa.mx