Process line makes bad castings good
By developing near 100% efficient, fully condensing, gas process heating and introducing precise computer controls to the entire process ISL expects to see CO2 reductions in excess of 13 tonnes per annum along with increases to both quality and capacity
Micro-porosity sealing specialist Impregnation Services has invested in a new high capacity, high efficiency process line to recover imperfect cast components.
“Micro porosity has always been an issue in cast metal components used in industries from automotive to domestic water delivery‟ says managing director Justin Benson. “Our processes use high vacuum and pressure cycles to drive very low viscosity resins deep under the surface of the part. Once in place, the resins are washed clean from the surface and are then thermally cured to form a pressure tight seal. Parts that would otherwise have been re-cast can be recovered at a fraction of the cost to both our customers and the environment.‟
The new ‘Pressuretite-8-HE’ high efficiency, eight stage batch sealing process was jointly funded by Impregnation Services (ISL), the Northwest Regional Development Agency (NWDA) and the European Regional Development Funds (ERDF).
The company says the hefty investment involved represents a significant turning point in the Company‟s 46 year history. By developing near 100% efficient, fully condensing, gas process heating and introducing precise computer controls to the entire process ISL expects to see CO2 reductions in excess of 13 tonnes per annum along with increases to both quality and capacity.
The new Pressuretite-8-HE process line has been designed to be completely flexible so it will run efficiently regardless of whether it runs 10 or 600 „euro‟ 4 cylinder engine block castings in a single 8hr shift. Right now, that represents a huge over capacity for ISL but it means that it can seriously compete when the opportunity arises.
Originally based on Castle Street in Stalybridge the company moved to 5000 square foot premises on Cowhill Lane, Ashton-under-Lyne 10 years ago. Since completing a management buy in 2008 the new management team has been committed to constantly improving quality and process.
Finance director Rachael Benson says: “Without investment old school engineering businesses like ours will never reach their full potential. This project has stretched us to the limit both technically and financially but we are confident that it will attract new custom from at home and abroad.”
Designed in-house and built using local suppliers ISL believe that their success in completing this project proves that the North West still enjoys a wealth of engineering skills and abilities.
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