High-pressure sanitaryware casting
This page discusses high pressure casting machines in sanitaryware factories, their process steps, parameters, technologies, advantages, and drawbacks.
Overview: HPCM, or high-pressure casting machines, are innovative technology in the sanitary ware manufacturing business. These machines must be made by reputable organizations to reduce maintenance costs. Due of its high pressure and speed, high-pressure casting machines are difficult to maintain. The method used completes cycles in 20 minutes, compared to 8 hours for traditional bench casting. Technological improvement is shown by a 1920% increase in production speed.
Sanitaryware Factory High-Pressure Casting Machine
Pressurized casting machine Sanitaryware
High-pressure casting can produce 4–6 water closets, 36 pedestals, 24–30 washbasin-pedestal combos, or 44 Orissa Pans in one cycle. Machines create different sanitary ware models, therefore cycle times range from 20 to 45 minutes.
High-pressure casting machine process
High-pressure casting is comparable to other sanitary ware casting procedures, except it automates several operations. The PLC automates mold clamping, pipe and mold cleaning, slip filling, unloading, and demolding. In contrast to plaster casting, high-pressure casting uses resin molds. High layer formation casting rates are achieved by heating the slip to 45 degrees Celsius. Programed technologies are manually executed as needed to control the casting process.
Technologies' main stages
Moulds Closure: Mold clamp.
Filling molds using slip tank filling.
Under high pressure, layers form quickly (10–13 bars HP).
Decompression: Mold pressure reduction.
Air drainage of slide.
Air-dried ware for handling strength.
Venting mold to atmospheric air decompresses it.
Mold Opening: Clamp release and mold opening.
Water-demolding greenwares.
Air to Moulds: Cleaning or water removal.
Maintaining mould moisture during demolding.
Vacuuming molds during cleaning or extra water.
Pre- and post-conditioning pipe and mould flushing.
Parameters
Maintenance criteria for a high-pressure casting machine include:
Pressure: 10-13 bar
Slip temperature: 45-47ºC
1900–1920 litter weight
Fluidity: 320 ± 5
One-minute Thixotropic: 40 ± 5
High-pressure casting machine advantages
No mold changes, continuous production.
Low labor needs compared to output.
It takes up less area than bench and battery casting machines.
Operators need little competence to finish products well.
limitations
High startup costs.
High maintenance costs compared to other casting methods.
Producing sophisticated products like one-piece toilets is limited.
Conclusion
High-pressure casting machines produce quickly and efficiently like flights, but they cost money. It is most viable in industries with high workforce costs and less so in places with reduced labor costs.