Webac Gesellschaft für Maschinenbau mbH

Postfach 14 66, 53864 Euskirchen
Roitzheimer Str. 180, 53879 Euskirchen
Germany
Telephone +49 2251 9460-0
Fax +49 2251 9460-49
info@webac-gmbh.de

Location

Hall map

GIFA 2015 hall map (Hall 17): stand A41

Fairground map

GIFA 2015 fairground map: Hall 17

Our range of products

Product categories

  • 05  Moulding and core making
  • 05.04  Moulding and core making machines, accessories
  • 05.04.01  Gassing equipment for moulds and cores

Gassing equipment for moulds and cores

  • 05  Moulding and core making
  • 05.04  Moulding and core making machines, accessories
  • 05.04.02  Dosing devices for binders and additives

Dosing devices for binders and additives

  • 07  Moulding sand preparation and sand reclamation
  • 07.01  Moulding sand preparation
  • 07.01.01  Moulding sand preparation machines and plants

Moulding sand preparation machines and plants

  • 07  Moulding sand preparation and sand reclamation
  • 07.01  Moulding sand preparation
  • 07.01.02  Moulding sand mixer

Moulding sand mixer

  • 07  Moulding sand preparation and sand reclamation
  • 07.01  Moulding sand preparation
  • 07.01.06  Sand coolers

Sand coolers

  • 07  Moulding sand preparation and sand reclamation
  • 07.01  Moulding sand preparation
  • 07.01.08  Sand precoating plants (for shell moulding)

Sand precoating plants (for shell moulding)

  • 07  Moulding sand preparation and sand reclamation
  • 07.02  Sand reclamation, plants and machines
  • 07.02.01  Sand reclamation of clay bonded moulding sands

Sand reclamation of clay bonded moulding sands

  • 07  Moulding sand preparation and sand reclamation
  • 07.02  Sand reclamation, plants and machines
  • 07.02.03  Sand reclamation of synthetic resin bonded sands

Sand reclamation of synthetic resin bonded sands

Our products

Product category: Gassing equipment for moulds and cores

Cold box gassing

For many years, Webac-Michel gassing units equipped with metal bellows dosing systems have set the standard for gassing devices. Recently, we have taken things one step further. For dosing, the newly developed GWP gassing units use a magnetically coupled gear pump and a flow meter instead of a dosing cylinder.


The gear pump transports liquid amine through a ring pipeline. Depending on the pre-set dosing volume, the desired volume of amine is extracted through the dosing valve and the flow meter from the ring pipeline system and fed to the flow heater. To ensure exact dosing, a flow meter with a volumetric flow range of 0.005 to 0.7 l/m is used. The flow heaters have been specially designed for Webac and allow for the most effective production of amine gas from liquid amine.


Thanks to the tried and tested proportional valve technology, the gassing time, end pressure and pressure build-up time can be adjusted to suit the actual requirements. Operators can thus achieve optimised core hardening with shortest possible gassing times. The gassing units are equipped with dedicated PLCs that communicate with the core shooter, which starts the gassing process. For greater data exchange, the PLC can be equipped with a network interface. Alternatively, the gassing unit control system can be integrated into the PLC of the core shooter. In this case, the gassing unit is wired to terminals. The pressure build-up and flushing times can be set at the control device of the gassing unit or supplied via data transfer from the PLC of the core shooter.


The GWP gassing units are available with 8 kW or 12 kW heating output, catering for the optimised gassing of cores of up to 120 kg in weight. In addition to the new models, some of our older, well-established gassing units are still available, offering customers a cost-effective alternative to the latest technology.

↓Gassing unit GWP 150-12

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Product category: Dosing devices for binders and additives

Binder dosing

Accurate binder dosing is a prerequisite for economical core production. In our units, the binder is metered in pneumatically operated dosing cylinders. Depending on the requirements, the unit caters for the dosing of fixed quantities by means of proximity switches, or for continuously adjustable binder quantities. Our machines provide dosing accuracy with less than 0.5 % deviation from the scale value combined with excellent repeat accuracy.


Depending on the liquid to be dosed, the dosing cylinder is available in aluminium, stainless steel or glass. The equipment is sealed with environmentally friendly recyclable PTFE.


As binder systems and batch sizes vary, our automatic dosing units are available in various designs and sizes with dosing cylinder capacities from 100 cm3 to 14,000 cm3.


Binder dosing requires of course suitable binder storage. For this purpose, we offer exchange barrel and exchange tank stations. Depending on the site conditions, the automatic binder dosing units can be connected directly to the tank/barrel storage system, or are supplied with binder through pumps and buffer tanks. The station design conforms to the requirements of article 19 of the German Federal Water Act WHG. The collecting trays are TUEV-approved.

↓Tank storage system with automatic binder dosing unit

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Product category: Moulding sand preparation machines and plants

The best casting requires good sand

As well as a good moulding machine, the quality of the sand is crucial in determining the quality of the cast pieces.


Sand preparation serves to:
• prepare the necessary amount of sand
• screen out lumps and metallic impurities
• homogenise the spent sand
• freshen up the sand in response to the stress from the casting process
• ensure exact additions of new sand, bentonite, coal dust, and filter dust,
as well as the addition of water for cooling and moistening

We create an individualised layout according to the client’s wishes and the process requirements. The proposal is discussed with the client, and is adapted to his wishes. The result is an optimised tailored plant design.

We manufacture all key components of sand preparation ourselves, such as return sand coolers, form sand mixers, and polygonal screens. This way, we ensure that all the knowledge from our manufacturing and from the operating experience of our clients flows into the continuing further development of our products.

Even during installation, the client’s staff is trained by our experienced specialists in the functioning and construction of the plant. In addition, intensive training sessions take place during commissioning.

After acceptance of the plant, Webac staff continues to be available for technical support. In addition, we support our clients with a rapid and flexible replacement parts service.

↓Schematic diagram of a sand preparation plant:
1 Polygonal screen
2 Intermediate bunker
3 WASK return sand cooler
4 Bucket conveyor
5 Spent sand bunker
6 New sand bunker
7 Additive storage
8 Binder scales/injection
9 SPEEDMULLOR
10 Control panel

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Product category: Moulding sand mixer

Webac Sandmixer

Well prepared sand results only if sand, water, bentonite, and other additives are optimally mixed together. Every grain of sand must be surrounded by bentonite.

The advantages of the Webac Sandmixer are:
• effective dosing of additives
• optimum dosing of water via the wear bottom
• addition of the additives (bentonite, coal dust, new sand etc.) by injection of binders into the sand bed
• gentle handling of the sand grains through a kneading action

By applying a rubber coating as a lining for the mixer, and through the kneading action of the mixing wheels which are also rubber-coated, an optimum coating of the sand grains with bentonite is achieved. This type of preparation is extremely protective. The plows fixed to the cross-head ensure that the sand is mixed efficiently.

Economy is the measure of all things

The advantages of the Webac Sandmixer are reflected not only in speed, efficiency, and the sand quality obtained, but also in its economy. This is visible even in the way that the mixer is constructed. It was designed in such a way that all maintenance operations can be carried out rapidly and simply. Where the heaviest stresses occur, the mixer wall is coated with a rubber lining. The mixing wheels are fitted with rubber rings. To increase the durability of the mixer, many machine parts are made from cast metal. A single motor, one gearbox, and the rotating central cross-head ensure working safety and minimum maintenance. Mix outputs up to 140 t/h mean that the Webac Sandmixer is a sand mixer which is convincingly economical.

↓Webac Sandmixer WSM

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Product category: Sand coolers

Return sand cooler

In addition to the Webac Sandmixer, the return sand cooler is a key component of sand preparation. Form sand moisture content and temperature are decisive criteria for the behaviour of sand during forming. Temperature reduction takes place in the return sand cooler. In addition, the moisture content is adjusted to the optimum value for reactivation in the return sand bunkers.

To achieve this, various processes take place in the cooler:
• Transport and mixture of the sand
• Moistening of the sand
• Evaporation of the cooling water
• Absorption of the water vapour

WAC batch coolers


Webac’s patented batch cooler represents a milestone in the further development of sand preparation. As well as the high cooling efficiency, it offers the advantage of an early bentonite addition. Before starting the cooling cycle, the spent sand is weighed in two scales. With the aid of forming and casting parameters, and of the measured weight of sand, the amount of bentonite to be added is calculated. The cooling process is divided into two phases. During the first phase the sand is cooled. At the end of the cooling period the second phase begins. The air supply is reduced to a minimum, and two binder injectors blow the bentonite into the sand bed. At this point the mixing time starts. After the two large emptying doors have been opened, and the batch cooler is completely empty, the cooling cycle ends.

WASK continuous coolers


The WASK type return sand cooler is designed for continuous operation. Cooling is largely achieved by evaporation of the cooling water. The resulting water vapour is extracted with the cooling air from the cooler. The cooling air is blown in through large openings in the cooling basin below the level of the sand. The sand is fluidised and there is a large surface for evaporation. To minimise the carry-out of fine particles, great value is placed on low air speeds when designing the coolers.

↓Continuous cooler WASK

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Product category: Sand precoating plants (for shell moulding)

Planning and advising, the basis for success

The world-wide use of Webac plants reflects and emphasizes the success of the concepts with our installations. Our concept which has come a philosophy bases on the following features:
• Long life through quality of alle components
• Flexibility with individual customer solutions
• Consistency with practice-related developments
• Competence with advising and attendance also after commissioning of the plants

Research, development and many years of practical experience helped the basic principle of sand coating to become a perfectly proven success. Special customer demands and a great variety of productin tasks show the importance of designing each coating installation in a flexible way and of adapting it to the specific requirements.

Our advising service covers all kinds of details beginning with the question whether to have a new construction building or to use existing halls, continuing with different types of processes and procedures for different sands, and finishing with the question if the sand coating plant is to use one type of quartz sand, various types of sand or even zircon or chromite sands. The same applies with resins. How many resins or a mixture of different resins are required? No matter how the task to be solved may be formulated: In any case, our installations are designed and realised to fully meet the demands of our customers.

The flow of process

First of all, the raw sand is heated in the sand heater to reach its process temperature. Here, the sand heater works in time with the mixer. This way, the sand reaches its process temperature as soon as the mixer is ready to take a new batch.

Sand and resins are fed into the mixer to be uniformly mixed within a few seconds. In the course of this process, the resin takes heat from the sand and starts melting. With the hot coating process, sand grain is provided with a uniform resin coating. Subsequently, hexamethylene-tetra-mine dissolved in water is added as hardening agent. In case of using liquid resins, calcium stearate is added as hardening agent. For additional cooling, air can be blown through the sandbed. In accordance with cooling requirements, clean water controlled by a water meter can be additionally fed into the mixer. The immediate vaporization of the water cools the the sand quickly and thus avoids any undesired reactions of the resin and the hardening agent Before the sand is discharged from the mixer, calcium stearate is automatically added in accordance with the preselected recipe. This improves the flow characteristics of the sand.

When the coating process in the mixer has been finished, the sand charge is fed onto the gyra screen. Existing sand lumps are disintegrated to sand grain size and the sand is conveyed into the fluidised bed cooler. The fluidised bed cooler cools the sand to storing temperature. If required, it is possible to add a fine screen.

↓Sand heater SPH

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Product category: Sand reclamation of clay bonded moulding sands

Mechanical regeneration

Used sand must be prepared for mechanical, thermic, or multi-step regeneration by breaking up, screening, drying, and cooling. The KGT Jet Reclaimer is outstandingly suited to mechanical regeneration. The Jet Reclaimer works on the principle of air jet friction.

The process steps are:
• Drying / embrittlement (if necessary)
• Cleaning by grain-against-grain friction.
• Sifting and cooling

The Jet Reclaimer is constructed in such a way that the air which is blown in through the jets in the floor fluidises the sand. At the same time the sand is sifted and cooled. As required, the air is heated to approx. 400 °C, and can be used for drying and for embrittling the binder sheath. In the centrally located blastpipe with the jet positioned under it, and the friction bell sited above the blastpipe, a gyratory air and sand mixture results, in which extensive cleaning of the grains occurs.

The main properties of the Jet Reclaimer are:
• batch-wise operation
• high cleaning efficiency with low grain damage
• no moving parts in the sand, and therefore less wear
• multiple process steps occur in a single compact piece of equipment

Depending on the quantity of sand for regeneration, the Jet-Reclaimer can be supplied in single or multi-pipe models.

↓Mini Jet test plant

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Product category: Sand reclamation of synthetic resin bonded sands

Mechanical regeneration / Thermic regeneration

Mechanical regeneration

Used sand must be prepared for mechanical, thermic, or multi-step regeneration by breaking up, screening, drying, and cooling. The KGT Jet Reclaimer is outstandingly suited to mechanical regeneration. The Jet Reclaimer works on the principle of air jet friction.

The process steps are:
• Drying / embrittlement (if necessary)
• Cleaning by grain-against-grain friction.
• Sifting and cooling

The Jet Reclaimer is constructed in such a way that the air which is blown in through the jets in the floor fluidises the sand. At the same time the sand is sifted and cooled. As required, the air is heated to approx. 400 °C, and can be used for drying and for embrittling the binder sheath. In the centrally located blastpipe with the jet positioned under it, and the friction bell sited above the blastpipe, a gyratory air and sand mixture results, in which extensive cleaning of the grains occurs.

The main properties of the Jet Reclaimer are:
• batch-wise operation
• high cleaning efficiency with low grain damage
• no moving parts in the sand, and therefore less wear
• multiple process steps occur in a single compact piece of equipment

Depending on the quantity of sand for regeneration, the Jet-Reclaimer can be supplied in single or multi-pipe models.

Thermic regeneration

Thermic regeneration plants are best used for used sands which are organically bound. We have developed flow bed ovens and flow bed coolers specifically for these applications, and they have proven themselves many times over in foundry operations. Flow bed technology permits optimum heat transfer, protective handling of the sand with optimum regeneration quality, and high sand output. The heat recovery used and the exact temperature control adjusted to the process result in low energy requirements which boost the economic operation of the plant.

The patented control of oven level and sand removal guarantees a consistent handling period and a defined passage of the individual sand grains through the oven.

A further application of the sand regenerator is the recovery of sands bound using furan resin. In combination with our through-feed mixers, we offer complete systems for the creation of furan resin forms, via knock-out grids, and through to regenerators and the re-use of the regenerated sands. Following an exact analysis of the customer’s situation, the furan sand regenerators are designed and then made to measure. In addition to the effectiveness of the regenerator, its environmental friendliness plays a very significant role. This begins with the economical use of the energy needed, goes on to the high output of sand from the regeneration process, and ends with the reduction of all resulting emission, whether this is dust or noise.

↓Thermic sand regeneration plant

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About us

Company details

The origins of the company, which is now active worldwide, go back to 1931, when the AB Westin & Backlund company was founded in Stockholm. The growing demand for machines and complete plants led to the foundation of a German subsidiary, Webac Gesellschaft für Maschinenbau mbH, in 1963, with headquarters in Euskirchen. As the founding families have gradually withdrawn from the company, Webac GmbH is now entirely owned by Webac Holding AG, Munich.


The Michel company was taken over in 1993 to extend the product range. This purchase gave Webac a significant market boost in the area of core sand preparation and gassing technology. The same aims were achieved in 1995 with the takeover of KGT. As well as the expertise in sand preparation, complete know-how on sand regeneration is now available to the customer, based on the experience gained from the many plants implemented. In addition to the current product range, Webac has recently successfully started to offer alloying agent dosing units for melting shops.


Depending on the customer’s wishes and options, we offer support for all project steps, from project analysis through feasibility studies up to project implementation including vendor selection, purchasing, installation, and commissioning. We rely on competent advice in order to present customized solutions. These solutions are implemented according to the specifications with the utmost care and expertise. Our goal is to offer our customers everything from one source, referring both to our consulting services, planning and execution, as well as the proposed plant and machinery. All our machines and plants are key components of our own designs and are built in our workshops. Even after the order processing, we provide our customers with any help and advice.


To document the quality standards which have for many years applied both to internal processes and to products, Webac has been certified to DIN EN ISO 9001 since 2002.


Webac now has four sites: the headquarters in Euskirchen, a manufacturing plant for core sand units in Radofzell on Lake Constance, Webac S.R.O. in Pribram (Czech Republic) – a supplier of steel construction components, and Webac Maskin in Stockholm - a sales subsidiary for the Scandinavian region.

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Company data

Sales volume

10-49 Mio US $

Export content

max. 25%

Number of employees

20-49

Foundation

1963

Area of business
  • Moulding sand preparation and sand reclamation
  • Transportation and storage