THE ROMI FOUNDRY:
Castings of high technical reliability and excellent characteristics
The Romi Foundry is a division of Industrias Romi S.A., a Brazilian company and a leader in the four market segments it serves: Machine Tools, Plastic Injection Molding Machines, High Precision Adjustable Boring Systems and Rough and Machine Castings.
The Foundry is located in a 285,000 square foot plant equipped with the most modern machinery such as electric induction furnaces. This technology enables Romi to produce more than 1% of all iron castings in Brazil and 3% of its exported production. One third of its total production is exported to the U.S. and Europe. Its major customer groups are automotive and industrial machinery companies supplying them with parts such as platens for plastic injection molding machines, bases for turning and machining centers, gearboxes for commercial vehicles and heavy duty tractors.
MELTING AREA:
Gray and Ductile iron high melting capacity
The Romi Foundry produces 2,000 metric tons a month of high quality gray and ductile iron castings. To achieve this production, the foundry is equipped with two automatically loaded electric induction furnaces, one a 1,100 kW furnace with two 10 metric ton capacity crucibles each.
Melt material is subject to strict tests before pouring and iron castings are produced in accordance with DIN 1691 standard (gray from GG 15 to GG 30 and ductile from GGG 40 to GGG 70) or its equivalent ASTM, SAE, BS and ABNT standards. The foundry also produces castings according to customers' specifications.
AUTOMATIC GREEN SAND MOLDING:
High dimensional reliability
The green sand molding line operates at high pressure and under the quick mold changing system. All process variables are SPC controlled. It is equipped to produce castings of up to 134 lb. (60 kg) of high dimensional reliability, at cycles of up to 100 molds per hour.
NO-BAKE MECHANIZED MOLDING:
The system consists of two lines with the following features:
- Line with capacity for parts up to 1,100 lb. (500 kg) and production of 120 molds per day.
- Line with capacity for parts up to 2,200 lb. (1,000 kg) and production of 30 molds per day.
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NO-BAKE HANDMOLDING:
Versatility and technical conformity
The no-bake manual molding system is equipped with a complete materials handling system for moving cores and molds, suitable for the production of castings up to 55,000 lb. (25,000 kg).
Highly qualified and skilled technicians are capable of producing castings of certified technical and dimensional conformity.
Aiming at obtaining the best quality and costs reduction, resources such as pit molding, mold heat treatment through cooling curve analysis by termopar and SPC are used.
PROCESS ENGINEERING AND PATTERN SHOP:
Technical experience and capability
The Romi Foundry has an engineering sector equipped with a qualified, trained and experienced technical team. Available CAD and FMEA resources can be used for both tooling design and process. The sector also follows up samples development and compliance to international standards and customers requirements.
It has its own pattern shop with highly qualified and experience personnel. It is suitable for developing prototype and production of wooden, cast iron, aluminum, resin and Styrofoam patterns.
COMMITMENT TO QUALITY:
The Romi Foundry has not only been ISO 9002 certified since 1994, the Foundry has received numerous certifications from its major customers.
Its laboratory is equipped with the latest equipment such as optical spectrometers, tensile strength testing machine, carbon and sulfur analyzer, wet tensile strength and ultra sound machines.
Highly qualified engineers and technicians constantly develop new materials aiming to attain quality improvement and cost reductions. Physical, chemical and metallographic tests are carried out by the Romi Foundry. The Foundry also approves samples, prepares technical reports and renders service to customers.
MACHINING SUPPORT:
Assured quality with flexibility
The Romi Foundry is capable to supply machined castings. The facilities, the experience and know-how of Industrias Romi S.A. has grown during decades of manufacturing machine tools. This ensures that you are purchasing quality machined castings.
Its concentration of latest generation machine tools includes manufacturing cells equipped with CNC turning and machining centers of high quality productivity, able to operate with high series and large range of products.
The Romi Foundry renders complete technical assistance to customers during the manufacturing process.
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