Company Presentation

DENİZCİLER DÖKÜMCÜLÜK SAN. VE TİC. A.Ş.
COMPANY PRESENTATION 2015
About Us :
 Founded in 1978
• Total production capacity app. 24.000 Tons/year.
 Total area 25.000 sqm., covered production facilities
14.000 sqm.
 200 qualified employees.
 Our main activity is;
 the production of gray and ductile iron castings.
 their machining
 heat treatment, coating and hot dip galvanizing.
 Single Part weights; from 0,5 kg./piece to 15000 kg./piece
 Various approvals including ISO 9001,
Where we are:
Corporate Information :
Full Name & Address:
DENİZCİLER DÖKÜMCÜLÜK SANAYİ VE TİCARET A.Ş.
Kutlu Aktaş Cad. No:23 ALOSBI 35800 Aliağa IZMIR/TURKEY
Legal Form :
Incorporated Company
Establishment Date :
03.12.1981
Tax Registration Office :
Hasan Tahsin Tax Office
Tax Id. Number: 292 000 3925
Paid Capital :
Memberships :
10.000.000 Turkish Liras
Aegean Chamber of Industry No: 10408
Aliağa Chamber of Trade No : 3964
Our Staff :
By Position
Manager
Administration
Chief
Foreman
Master
Number
7
By Education
Number
University Graduate (Engineer)
13
20
University Graduate (Others)
14
1
Vocational College Graduate
7
13
8
Technical High School Graduate
30
High School Graduate
18
Direct Workers
161
Others
128
Total :
210
Total :
210
Production Processes :
Pattern Design & Simulation
• The CAD/CAM software TOPSOLID , used for designing the patterns, enables us to make 3D Models of the parts to be casted and also
to determine the part weights.
• 3D Modelling is also the starting point for our casting simulation program QUIKCAST.
• Before the actual casting process, the possible problems that may arise from the pattern design or the casting parameters are
determined and the corrective actions are taken in advance to resolve these identified problems.
• The optimised casting parameters and the molding design leads to minimized quality problems , increasing our production efficiency.
• These optimised parameters are than integrated into product sheets to maintain the best quality during the serial production.
• The prepared samples will be checked with 3D Laser scan Faro Arm. The scanned data is checked with the original Cad data received
from customer.
Pattern Production
• Being fully aware of the fact, that quality castings require quality patterns,
we attach great importance to pattern production with accurate dimensions
and tolerances.
• Depending on the required lifetime and the selected moulding line, patterns
are made accordingly of wood, aluminium, iron or polystrene.
• Our well equipped pattern shop with CNC Centers and our experienced
team enables us to fulfill our customers’ requirements in terms of new
patterns or modifications within favourable lead times.
• The patterns are registered in our ERP system and stored properly in our
warehouse after final controls for easy access and maintenance.
Sand Preparation
•Our fully automatic sand preparation plants are PLC controlled and enable us to achieve best possible results in terms of surface quality
for our castings.
• For sustainable sand quality, mix preparation is controlled at every batch for compactability, green strength and moisture.
•Furthermore, samples are also manually taken and cross checked in our quality lab to ensure that the required specifications are met.
• 1 x Simpson Speedmüller 85B Sand Mixer 60 Tons/Hour
• 1 x Webac Müller Sand Mixer 50 Tons/Hour
• 2 x Hartley Sand Control System
• Besides green sand system, we also utilise furan system for
our semi-automatic moulding line, as well as for hand moulding.
• Omega Spartan 2 Sand Mixer (10 Tons/Hour) with cooling and
reclamation system.
Core Making
• According to the requirements of the castings demanded by our customers, we
utilise different kinds of base materials for the production of cores.
• Following materials are used for core production.
• CO2 Sand
• Furan Resin Sand
• Chrome Ore Sand
• Shell Moulding Sand
• Utilised machines are;
• 3 x 80 lt capacity cold box machine (CO2 + Carbophen)
• 1 x 60 lt capacity cold box machine (CO2 + Carbophen)
• 4 x 25lt capacity cold box machine (CO2 + Carbophen)
• 6 x 5lt. capacity cold box machine (CO2 + Carbophen)
• 4 x 2lt. capacity shell and hot box core machine
Moulding
•The molding process is rather diversified and depends on the
design , complexity, weight and accuracy of the casting.
• One of our three full automatic molding lines for parts up to 90 kg
single part weights is our DISA MATCH 24 x 28 (Horizontal)
• 120 Moulds/ Hour capacity
• Mould dimensions 613 mm x 713 mm x 500 mm
• 2 x Hunter HMP 20 x 24 automatic moulding lines.
• 100 Moulds/ Hour capacity
• Mould dimensions 508 mm x 613 mm x 400 mm
• Single part weights up to 90 kg.
• Automatic pouring and cooling lines.
• 1 x Semi-automatic (flaskless) molding line with rollover, operating with furan
resin system (OMEGA, UK)
• Spartan 2 Sand Mixer 10 Tons/Hour (OMEGA, UK)
• Single part weights up to 350 kg.
• Mould sizes 1250 mm x 1800 mm x 900 mm
Hand Moulding
• Prototypes, castings not suitable to our moulding line in terms of part weight and dimensions, as well as parts with smaller
quantities are produced with this method.
• To this end we have flasks in various dimensions. Flasks with sizes up to 4000 mm x 4000 mm are available.
• Single part weights up to 10000 kg for ductile iron and up to 15000 kg for gray iron.
Melting & Pouring
• Our melting capacity is 14,2 Tons/Hour,
• Following induction furnaces are operative at our foundry;
1 x 7200 kg/hr 4250 kw medium frequency furnace
1 x 4500 kg/hr 2750 kw medium frequency furnace
1 x 1500 kg/hr
800 kw medium frequency furnace
1 x 1000 kg/hr
600 kw medium frequency furnace
Fettling
• After cooling down for specified time periods, the in gates, feeders, as well as the risers of the casted parts are removed. Than the
residual molding sands are removed in suitable shot blasting machines and parts are subjected to quality control to determin their status.
• The castings approved by our quality staff are than forwarded to the work stations, where they are grinded for their end rough
dimensions.
• For these operations we utilise the following equipments;
•
•
•
•
1 x continuous hook type shot blasting machine (2400 mm x 1500 mm x 1500 mm - 10 Tons/hour)
1 x tumble type shot blasting machine ( 10 Tons/hour)
3 x hook type shot blasting machines (1400 mm x 1500 mm x 1500 mm 2 Tons/hour)
3 x tumble type shot blasting machines ( 1000 kg / hour - ø 600 mm)
•10 x wheel grinding machines - 600 mm diameter, 60m/sec
• Various air grinding tools
•2 Koyama 6 axis automatic grinding machines
Machining
• The parts casted in our foundry are delivered as machined at
customers’ request.
• Following machinery is in use in our machining shop
• Machining is also outsourced from regional machining
shops in case of large order quantitites.
• 1 x Vertical CNC 3 Axis (Quaser)
x= 1270 mm , Y= 700 mm , Z= 600 mm
• 1 x Vertical CNC 3 Axis (Ajan)
x= 900 mm , Y= 700 mm , Z= 400 mm
• 1 x Vertical CNC 3 Axis (Ajan)
x= 700 mm , Y= 700 mm , Z= 300 mm
• 1 x Horizontal CNC Lathe (Takisawa)
ø 450 mm, Y= 762 mm.
• 1 x Conventional Lathe
ø 660 mm, Y= 2500 mm.
• 1 x Conventional Lathe (Tos)
ø 520 mm, Y= 2000 mm.
• 1 x conventional Lathe
ø 660 mm, Y= 3000 mm.
• 8 x Column Drilling Machines ø 30 mm
Quality
Microstructure Analysis
with Microscope to magnify 1500X
FARO 3D Measuring Arm/ Faro Gage Lazer
Scan
Chemical Analysis with spectrometer
• 1 x OBLF for 15 elements
• 1 x OBLF for 18 elements
hardness tester 3000 Kg ,
Ball Ø10 mm
Tensile Testing,
Compression Testing,
Bending Testing
Capacity 20 tons
Ultrasonic Inspection (Karl Deutsch)
Penetration 120 mm
Coating
• According to customer specifications the primer coating is
perforned at our dipcoating line.
• Hot dip galvanising is also performed in-house.
Packing & Delivery
• The suitable delivery method is determined mutually with our
customers .
• Labelling is done according to customer specifications.
• According to their weight and dimensions, parts are delivered on
Euro pallets, in wooden boxes and crates, covered with strectch
film.
• Loads are secured properly to avoid any kind of transport
damage.
For machined parts suitable anti-corrosion materials are used.
Industries Served :
Machine Building Industry
Part Name
Material
Weigt
Dimensions
Part Name
Material
Weigt
Dimensions
Gearbox Cover
GGG 50
41 kg
480 x 530 x 150
Reduction Housing
GG 25
12,5 kg
200 x 180 x 150
Part Name
Material
Weigt
Dimensions
Part Name
Material
Weigt
Dimensions
Gearbox
GGG 70
160 kg
470 x 560 x 440
Shaft Cover
GG 25
60 kg
800 x 450 x 500
Part Name
Material
Weigt
Dimensions
Part Name
Material
Weigt
Dimensions
Connector
GGG 60
14 kg
400 x 200 x 310
Support
GG 20
21 kg
450 x 300 x 200
Part Name
Material
Weigt
Dimensions
Part Name
Material
Weigt
Dimensions
Compressor Cylinder Head
GG 25
8 kg
400 x 200 x 100
Gearbox Body & Cover
GG 20
16 kg – 8 kg
250 x 200 x 410
Part Name
Material
Weigt
Dimensions
Reduction Housing
GGG 50
9 kg
300 x 200 x 140
Part Name
Material
Weigt
Dimensions
90° Shaft Cover
GG 40
45 kg
700 x 600 x 500
Part Name
Material
Weigt
Dimensions
Part Name
Material
Weigt
Dimensions
Gearbox Cover
GG 25
125 kg
1200 x 1000 x 450
Air Valve Housing
GG 25
12 kg
250 x 400 x 120
Pump & Valve Industry
Part Name
Material
Weigt
Dimensions
Part Name
Material
Weigt
Dimensions
Water Pump Body
GG 25
32 kg
700 x 600 x 240
Pipe Coupling
GGG 45
32 kg
DN 300
Part Name
Material
Weigt
Dimensions
Part Name
Material
Weigt
Dimensions
Cooling Compressor Body
GGG 25
120 kg
1000 x 1000 x 650
Pump Casing
GG 25
70 kg
553 x 620 x 220
Part Name
Material
Weigt
Dimensions
Part Name
Material
Weigt
Dimensions
Impeller
GG 25
15 kg
Ø 300
Part Name
Material
Weigt
Dimensions
Part Name
Material
Weigt
Dimensions
Valve Body
GGG 40
250 kg
DN 700
Tapping Saddle
GGG 40
45 kg
500 x 225 x 180
Part Name
Material
Weigt
Dimensions
Actuator Housing
GGG 50
590 kg
700 x 500 x 550
Part Name
Material
Weigt
Dimensions
Adaptor Body
GG G 40
8 kg
DN 150
Part Name
Material
Weigt
Dimensions
Part Name
Material
Weigt
Dimensions
Impeller
GG 25
15 kg
Ø 300
Slide Clamp
GGG 40
10 kg
250 x 100 x 150
Agricultural Machinery Industry
Part Name
Material
Weigt
Dimensions
Part Name
Material
Weigt
Dimensions
Gearbox Cover
GG 25
28 kg
500 x 350 x 180
Cover
GGG 50
18 kg
300 x 200 x 240
Part Name
Material
Weigt
Dimensions
Part Name
Material
Weigt
Dimensions
Bracket
GGG 40
12 kg – 15 kg
450 x 350 x 200
Shaft Extension
GGG 40
40 kg
450 x 200 240
Part Name
Material
Weigt
Dimensions
Part Name
Material
Weigt
Dimensions
Shaft Cover
GGG 50
9 kg
300 x 200 x 140
Loading Arm
GGG 40
14 kg
400 x 200 x 150
Civil Engineering Industry
Part Name
Material
Weigt
Dimensions
Tube Fittings
GGG 40
0,5 kg – 6 kg
¾”-2”
Part Name
Material
Weigt
Dimensions
Manhole and Cover
GG20 - GGG 40
11 kg – 18 kg
400 x 400 x 400
Some of Our References :
Contact Informations :
ADDRESS: KUTLU AKTAŞ CADDESİ NO:23 ALOSBİ ALİAĞA
35800 İZMİR - TURKEY
TEL: 00 90 232 621 55 02
FAX: 00 90 232 621 55 04
WEB: www.denizcast.com
EMAIL: [email protected]
THANKS FOR YOUR ATTENTION