Magaldi has a long history of driving innovation in the Turkish metal casting market and has earned the trust of leading foundries with innovative, performance-oriented solutions. Recently, this success and experience has become visible in the collaboration with Dirikanlar Otomotiv San. Tic. Ltd. Şti., an important Turkish automotive supplier.
Investing Strategically while Considering the Integrated System
Dirikanlar Otomotiv chose Magaldi in 2022 to implement a fully integrated solution at its new iron foundry in Aksaray. The cooperation had clear goals when it came to the optimization of mold handling, deflashing, casting cooling and sorting processes. At the same time, the project was aiming at improving casting quality, operator safety, efficiency as well as the environmental performance.
Two core Magaldi technologies are combined in the solution:
- The Superbelt® conveyor system for transporting molds and hot sand
- The Magaldi Casting Cooler (MCC®) for controlled casting cooling, integrated deflashing, and sorting
These systems were integrated seamlessly, thereby allowing Magaldi to create a continuous, optimized process flow that reached from mold punching, to shakeout and final cooled casting output.
Ensuring an Efficient, Clean Mold Transport thanks to Superbelt®
The Superbelt® conveyor can handle up to 78 t/h of molds at temperatures up to 700 °C and can transport them smoothly from punching to shakeout.
The vibration-free operation is one of its key advantages and dramatically reduces airborne silicate dust, which is a critical factor when it comes to improved working conditions for employees inside the foundry.
Aditionally, enclosed covers create a fully sealed conveying path, which minimizes cleaning requirements while ensuring enhanced operator safety.
With this system, a solid foundation for efficient and stable foundry operations is laid, thanks to its ability to withstand extreme heat while maintaining continuous material flow and significantly reducing dust emissions.
Achieving Optimal Casting Results Through Precise Cooling: The Magaldi Casting Cooler (MCC®)
The Magaldi Casting Cooler (MCC®) takes over the critical cooling phase after shakeout.
The system gradually reduces casting temperatures from approximately 550 °C to around 100 °C in a controlled manner using ambient air. This gradual cooling process prevents thermal shock and significantly reduces the risk of:
- Cracks
- Residual stresses
- Defects on a microstructural level
Improved casting integrity and consistent part quality are the result. This is particularly crucial for demanding automotive applications with strict quality standards.
Deflashing and Sorting in One Integrated, Operator-Friendly System
The System features the integration of deflashing and sorting directly on the open section of the MCC®. This feature eliminates additional conveying stages and reduces process interfaces.
For repetitive manual tasks, the ergonomically designed belt ensures comfortable working conditions. A safer and more operator-friendly environment is guaranteed thanks to noise levels below 75 dB(A) and vibration-free movement.
Workers using the system benefit from:
- Reduced physical strain
- Enhanced workplace safety
- Stable and predictable process flow
Combining productivity and human-centered design further strengthens operational performance.
Raising the Bar for Contemporary Iron Foundry Operations
Thanks to Magaldi’s fully integrated solution, Dirikanlar Otomotiv achieved measurable improvements in:
- Operator safety
- Environmental and dust control
- Process efficiency
- Casting quality and integrity
The project sets a new benchmark for modern iron foundries in Türkiye and demonstrates how intelligent system integration can deliver both economic and technological advantages.
▶ Casting Cooling Technology Live in a Real-World Customer Testimonial Video
