Schmiedeberger Foundry: Improving efficiency through automated casting cleaning processes

In the casting cleaning department at Schmiedeberger Gießerei GmbH in the Ore Mountains, modern grinding and deburring machines from Reichmann are delivering significant efficiency gains. The use of the Maus 600 and 900 has significantly reduced the deburring time per component – from around five minutes to just about one and a half.

The investment costs pay for themselves quickly, particularly with suitable batch sizes of around 1,000 pieces or more, as well as with complex contours and recurring production runs; however, extremely favourable economic benefits are also achieved with smaller batch sizes, as the management confirmed upon enquiry. Throughput has increased three- to four-fold – whilst simultaneously reducing labour costs and improving quality. Complaints regarding grinding errors are now a thing of the past.

’s technological advancements The Maus 600 and 900 were introduced in stages. A key advantage lies in the CAD-supported offline programming, which enables fast changeover times and efficient planning, particularly for smaller production runs. Additional features such as clamping systems with downward force increase flexibility when handling workpieces of different shapes. Compared to robots, CNC machines usually score highly – particularly with new parts – thanks to shorter cycle times and a shorter ramp-up phase.

In-house expertise and bespoke fixtures

Thanks to its in-house toolmaking expertise, the Schmiedeberg foundry can manufacture the required fixtures quickly and precisely in-house. This not only saves time and costs, but also ensures repeatability and enables a rapid response to new requirements.

Smaller batch sizes are still processed manually – but how did the transition to automated processes go in practice?

A first-hand account from the foundry finishing shop – Toni Vogler tells his story

With experts such as Toni Vogler from the foundry finishing shop, technical know-how is incorporated directly from the shop floor into machine optimisation.

Toni Vogler knows the foundry finishing shop like no other. For years, he deburred and ground castings by hand – the grinding bench remains a familiar companion to this day. But for the past three years, he has also been working with Reichmann’s automated ‘mice’ – and with growing enthusiasm.

“It wasn’t love at first sight,” the man from the Ore Mountains admits candidly. When his bosses, Holger Kappelt and Dr Falko Uyma, entrusted him with the introduction of automated deburring, he was initially anything but comfortable with the idea. But with increasing experience, learning by doing and his extensive knowledge of the deburring process, Toni quickly became a valuable contributor to the machine programming.

True to his motto, “How can I go about this so I don’t have to turn it 500 times?”, he first familiarised himself with the Maus 600, followed later by the larger 900. Today, he says with a smile: “We’re now as close as two peas in a pod.”

Maus CAAT self-optimisation software

The integrated Maus CAAT self-optimisation software plays a special role. It relieves the operator of many steps, adapts quickly to the desired processes and automatically delivers precise results.

The Maus CAAT self-optimisation software is the only one of its kind on the market to date, and Reichmann has filed a patent application for it. It opens up entirely new possibilities for programme optimisation, which would be extremely time-consuming without digital support and would be virtually impossible to achieve on this scale. Maus CAAT therefore not only saves valuable time but also measurably increases productivity.”

At Schmiedeberger, the Maus 600 is primarily used for smaller castings weighing up to 25 kilograms, whilst the Maus 900 can easily handle components weighing up to 200 kilograms. After three years of automation, even the last reservations within the team have been dispelled. Staff appreciate the noticeable reduction in workload, the significantly shorter lead times – and the gain in precision.

Economic significance and market position

Schmiedeberg Guss is part of the DIHAG Foundry Group, which was first mentioned in historical records in 1412.

The company produces around 15,000 tonnes of castings annually, comprising some 3,500 different components weighing between 0.5 and 400 kilograms. The components are used in sectors such as rail transport, hydraulics and commercial vehicle manufacturing.

Within the DIHAG Group, Schmiedeberg acts as a flexible niche supplier serving a wide range of sectors and specialising in small-batch production – an advantage in times of economic volatility.

Industry situation and political framework conditions

As Managing Director Holger Kappelt and Foundry Manager Dr Falko Uyma report from their own experience, the German foundry industry is currently under considerable pressure – primarily due to high energy prices.

They are therefore calling for the following, amongst other things, to ensure the competitiveness of the sector:

• affordable industrial electricity,

• a realistic energy policy, e.g. with a more balanced assessment of technologies such as green hydrogen,

• greater social and political recognition of foundries as key industries in the fields of recycling, energy efficiency and manufacturing technology.

The importance of castings for mechanical engineering, infrastructure, mobility and energy technology is often underestimated. Yet foundries are essential to virtually every industrial value chain.

Outlook

Following a mixed year in 2024, the Schmiedeberg foundry is back to full capacity in 2025. Leading indicators from the hydraulics sector suggest a sustained positive trend. Investments in modern machinery and digital solutions are strengthening the site in the long term.

We wish you continued business stability and every success as you move into the future of the foundry and finishing shop.