Diapositiva 1 - Smeltek SA de CV

JULIO DIAZ TORRE # 112
CIUDAD INDUSTRIAL
AGUASCALIENTES, AGS 20290 Ph. +52 449 9710910
MEXICO
Our Policy
Smeltek, We are a work team, dedicated to
efficiency, and constant improvement in diverse
industrial processes. Our goal is to achieve
constant customer satisfaction. We provide the best
service, the highest quality products and comply
with the requisits established in the ISO:9001:2008
quality system.
.
Our History
SMELTEK S.A. de C.V. History goes back years, we initiated in 1974 solely as a foundry.
We started producing grinding balls for mills used in metallurgical operations.
Beginning iron melting using cupola furnaces, molding was performed in automatic
match plate machines using “green sand”. Iron balls ranging from ¾” to 4” in diameter
were produced. In 1976 the production of counterweights for forklift trucks started and
domestic customers like Allis Chalmers, Clark and Eaton used our parts for the domestic
market. To improve our foundry in 1990 we started replacing the cupola furnaces using
more environmentally friendly electric coreless induction furnaces, hereby reducing
emissions. Early in 1995 production of grinding balls stopped and we initiated mass
production of counterweights for export to USA. Since then SMELTEK has exported the
majority of its production.
Presently we have diversified to other industries as well, in the foundry we produce
castings in gray, ductile and steel, in 2012 we started the construction of a new plant in
Tepezalá county to supply stamped parts and assemblies, also we acquired and operate
equipment to produce expanded polystyrene products for the automobile industry as
well as for producing patterns used in the Lost Foam production of diverse castings, we
are also equipped with a modern CNC facility to produce machined parts as molds,
patterns, and dies; some of our current clients are:
NMHG. Inc, Lufkin Industries, Inc.; Beneteau Sailing Boats, Industrias John Deere SA de CV,
Case New Holland SA de CV., MCFA, Inc., Tachi-S SA de CV., Nissan Mexicana SA de CV
Our Location
We are located in the center of Mexico in a state called Aguascalientes. The state holds
some 1,000,000 inhabitants and is the industrial center of Mexico. We have four plants ,
three of them in the same spot in the “Ciudad Industrial” Industrial park of the city and
one in a rural area of the Tepezalá county in north Aguascalientes State. All with easy
access to Electricity, Water, Gas and transportation systems. All plants have a covered
surface of about 20,000 square meters with an office space of 946 m2.
Foundry Plant
Our foundry facility holds our melting, molding, pouring, grinding and paiting areas as
well as our EPS plant for pre-expansion and injection molding machines as well as our
CNC machining plant.
Melting área, four induction melting furnaces are operational, two with a capacity of
2,500 kW and one of 7,000kW as well as one of 1,000 kW; each of these furnaces have
pots for melting of 6,000 kG 15,000 kG 9,000 kG and 2,000 kG respectively.
Molding área; two no-bake mixers of 1,000# min. capacity as well as the Lost foam
molding line size of flasks is 44” diameter and 48” tall, a large line of lost foam flasks
for heavier castings up to 20 tons is in operation; we are installing a new vacuum
molding line for midsize castings up to 6 tons.
We also operate two shot blasting hanger tunnel type machines and different cranes as
well as an automatic chain hanged finishing and painting line.
Scrap Supply
For melting we have a good, consistent scrap supply of cast
Iron, structural and punching steel and lead ingots. Presently
we purchase the majority of our stock locally and in northern
Mexico. Our scrap mostly comes from clean auto cast, cast
iron shavings, cut structural steel and lead ingots. We use
also different ferroalloys and carburizers depending on
casting specifications.
Casting Processes.
Smeltek over the many years of production has had experience in
the varied casting processes. Currently we are transforming from
traditional molding of resin bonded sands and moving into new
areas of molding, as “Lost Foam Casting” and “Vacuum molding line”
both systems use loose silica sand as molding media and then
poured, in the EPS sytem the metal occupies and evaporates the
foam pattern which is replaced by molten metal.
EPS FOAM PLANT
Here we produce Expanded polystyrene parts used in the foundry
process as well as other parts small or large for diverse industries as
packing and automobile .
Casting Processes.
The advantages of the lost foam process are:-





Environmentally friendly (95+% of polystyrene is air)
Far greater tolerances can be achieved
Molding times greatly reduced
Minimize grinding (no cores nor parting lines)
Less impact on the environment as our sand can be re-used
continuously
 Certain features can be achieved and cast through Lost foam casting
where they cannot in conventional methods saving time and money
through machining.
Investigation
We work alongside the University of Alabama, USA who are fore
runners in the area of Lost foam casting research and development.
At present we are the only company world-wide who has dominated
the production of castings over 500 kg in the lost foam process
using loose sand as molding media. We have successfully poured
pieces up to 20T utilizing this process. We can run various fill
simulations of pouring to ensure casting soundness.
Innovation and adaptation in casting processes.
One of our most beneficial processes over the past years has been
the ability to design and manufacture castings to adapt with our
clients needs.
One of our success stories being that of NMHG who required a very
large mass in a very small area for their forklift trucks. We managed
to design and patent a process to manufacture counterweights that
have a cast steel exterior shell making them structurally strong one
piece casting having their interior filled with high density lead. Thus
making them heavier and capable of dealing with heavy loads in the
smallest of work spaces, we can produce lead castings of several
tons in weight.
Lead filled counterweights.
Counterweight is poured
using low carbon Steel.
No-Bake molds área produced,
here the cope, drag and Core
are assembled together to form
the counterweight mold.
FINISHED
WEIGHT
SHIPPING
COUNTER
READY
FOR
Once shaked out the shell
shows an even thickness
of wall allowing for lead
fill.
Lead is 100% enclosed
with welded stell plates
and once cool, K-coat
and primer paint are
applied.
Molten lead is used to fill
the steel shell to the
desired weight.
Lead filled counter weights.
Benefits of our lead core
counterweights:-
•
High density counterweights allowing
greater forklift truck capacity in smaller areas.
for
•
Smeltek`s patented unique molding method
allows for a much more aesthetic looking
counterweight.
•
Stronger external structure due the cast steel
shell.
•
Lower risk of accident in the workplace due to
design methods which reduce sharp edges and
acute corners
•
Competitive pricing.
Some of our foundry products.
Stamping Dies
Another innovative step taken by our company is the production of
stamping dies in different clases of cast iron using the lost foam
process, some of the benefits are:
•
Dies of varied shape and size can be fabricated in a fraction of the normal
production time, resulting in a structural sound one cast piece.
•
Competitive pricing.
Lost foam stamping dies
Completed Foam piece is
molded in sand ready for
pour.
Various foam section are
assembled to form the
Die mold.
Casting is machined to
drawing spec.
Poured and cooled rough
cast is shot blasted.
Sprue and runners are
removed.
Quality controls
To achieve customer standards we have found over
many years that applying good process controls is
the key. Through each stage of our process we
monitor the quality of our products with constant
data chemical, metallographic and dimensional
checks.
Quality controls
As part of our QA system we are
currently using a 3D scanner which has
the capability of capturing a 3D image of
PPAP or production castings. The
advantages to this system are huge time
reductions compared to other measuring
systems or conventional CMM, and
visual representations within the report
and references covering thousands of
points instead of only a few dimensions.
Machinery Spec
Brand
Type
Axis
Machining Dimensions (mts.)
Henri Liné
Tarus
Tarus
Hass
Thermwood
Cincinnatti
Milltronics
Yam
3 TOS
1 TOS
1 Cincinnatti
1 Cincinnatti
1 Cincinnatti
Creaform
Faro
Gantry
Gantry
Gantry
CNC Vertical mill
Gantry
CNC Horizontal Mill
CNC Vertical Mill
CNC lathe
Parallel Lathe
Parallel Lathe
Brush
vertical mill
horizontal mill
Handyscan
Arm
5
5
4
X= 3.05, Y=1.5, Z=0.95
X= 7.0, Y=2.1, Z=1.30
X=3.05, Y=1.5, Z=0.95
3
3
3
2
X=3.05, Y=1.8, Z=0.305
X=2.1, Y=0.91, Z=0.91
X=1.22, Y=0.62, Z=0.66
X=0.80, Y=0.30, 8 stations
X=3.05, Turn=0.70
X=1.5, Turn=0.60
X=0.45, Y=0.30,
X=1.22, Y=0.62, Z=0.66
X=1.22, Y=0.62, Z=0.66
3D Digital scanner
Silver model 3.05 Mts. Reach
CNC Machining plant
This facility is located within the same complex as the foundry.
Here we produce machined parts , patterns and stamping dies
for both internal and external clients. At our machining plant we
have operational:-
Stamping Plant
Our Stamping plant is called STAMPTEK and its simbol is :
It is located as the below plan about 50 km north of Aguascalientes
city. This facility covers an area of 300 Hectares and contains the
first of three buildings of 4000 m2 under roof each, the remaining
two of the same size are under construction.
PRESSES ESPECIFICATIONS
MM
MARCA
SERIE No
1
TISHKEN
6266 433
COT-S-A
6T
2
FEDERAL
22 210
22 Flyw heel
20T
3
BLISS
H - 70516
HP 53861
50T
4
KYORI
SSDC
60T
5
PERKINS
OBI
75T
6
AIDA
00220-6498
NC1-200
7
AIDA
10220-6634
NC1-200
8
AIDA
10220-6630
9
AIDA
10
VERSON
MODELO
CAPACIDAD
SPM
BOLSTER
AREA
SLIDE STROKE
DIE HEIGHT
SLIDE ADJUST
50
100
203.2
50.0
152.4
254.0
152 X 254
150
101.6
215.9
50.8
254.4
304.8
304 X 508
60
76.2
228.6
76.2
457.2
381.0
736 X 457
40-500
101.6
254.0
76.2
762.0
609.2
762 X609.2
20-60
152.4
304.8
101.6
355.6
304.8
609.2 X 762
200T
20-40
249.9
449.6
110.0
878.8
647.7
1389 X 838
200T
20-40
249.9
503.9
110.0
878.8
647.7
1389 X 838
NC1-200
200T
20-40
249.9
503.9
110.0
878.8
647.7
1389 X 838
10220-6584
NC1-200
200T
20-40
249.9
449.6
110.0
878.8
647.7
1389 X 838
20002
C2-200-60-42
200T
20-40
203.2
508.0
152.4
1524.0
1066.8
1524 X 1066
SLIDE AREA
11
WARCO
5198
200-2-108
200T
20-40
304.8
609.8
152.4
2743.2
1219.2
2743 X 1219
12
VERSON
12667
S2-300-120-48
300T
16
355.6
482.6
152.4
3048.0
1219.2
3048 X 1219
13
BLISS
C-50359-5
SE2-600
600T
16
406.4
609.6
914.4
304.8
2133.6
1371.6
2133 X 1371
14
BLISS
C137-03
SE2-600
600T
16
406.4
609.6
914.4
304.8
2133.6
1371.6
2133 X 1371
15
DANLY (double
action)
53-068301
D2-800-84-60
800/500T
12
508/660
1600
1524
254
1828 X 1066
2133 X 1066
2133 X 1524
16
ROSENQUIST
Hydraulic
300T
20
Hydrailic
406.4
1219 X 600
1219 X 600
17
BINFORD
Hydraulic
800T
20-60
Hydrailic
508
1270 X 406
1270 X 406
Employees and workers
This is our most valuable asset, therefore
we constantly train them to ensure that only
high quality products are going to be
produced.
We at Smeltek have open capacity to serve you in our different
areas, give us a call and surely you´ll find a and excellent
partner.
The smeltek Team thank you
for your preference