1 DENİZCİLER DÖKÜMCÜLÜK SAN. VE TİC. A.Ş. COMPANY PRESENTATION 2015
2 About Us : Founded in 1978 Total production capacity app Tons/year. Total area sqm., covered production facilities 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 kg./piece Various approvals including ISO 9001,
3 Where we are:
4 Corporate Information : Full Name & Address: DENİZCİLER DÖKÜMCÜLÜK SANAYİ VE TİCARET A.Ş. Kutlu Aktaş Cad. No:23 ALOSBI Aliağa IZMIR/TURKEY Legal Form : Incorporated Company Establishment Date : Tax Registration Office : Hasan Tahsin Tax Office Tax Id. Number: Paid Capital : Turkish Liras Memberships : Aegean Chamber of Industry No: Aliağa Chamber of Trade No : 3964
5 Our Staff : By Position Number By Education Number Manager 7 University Graduate (Engineer) 13 Administration 20 University Graduate (Others) 14 Chief 1 Vocational College Graduate 7 Foreman 13 Technical High School Graduate 30 Master 8 High School Graduate 18 Direct Workers 161 Others 128 Total : 210 Total : 210
6 Pattern Design & Simulation Production Processes : 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.
7 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.
8 The patterns are registered in our ERP system and stored properly in our warehouse after final controls for easy access and maintenance.
9 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.
10 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
11 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
12 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.
13 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
14 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 kg for ductile iron and up to kg for gray iron.
15 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
16 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 mm diameter, 60m/sec Various air grinding tools 2 Koyama 6 axis automatic grinding machines
17 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
18 Quality Microstructure Analysis with Microscope to magnify 1500X Chemical Analysis with spectrometer 1 x OBLF for 15 elements 1 x OBLF for 18 elements Tensile Testing, Compression Testing, Bending Testing Capacity 20 tons FARO 3D Measuring Arm/ Faro Gage Lazer Scan hardness tester 3000 Kg, Ball Ø10 mm Ultrasonic Inspection (Karl Deutsch) Penetration 120 mm
19 Coating According to customer specifications the primer coating is perforned at our dipcoating line. Hot dip galvanising is also performed in-house.
20 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.
21 Machine Building Industry Industries Served : Part Name Gearbox Cover Material GGG 50 Weigt 41 kg Dimensions 480 x 530 x 150 Part Name Gearbox Material GGG 70 Weigt 160 kg Dimensions 470 x 560 x 440 Part Name Connector Material GGG 60 Weigt 14 kg Dimensions 400 x 200 x 310 Part Name Reduction Housing Material GG 25 Weigt 12,5 kg Dimensions 200 x 180 x 150 Part Name Shaft Cover Material GG 25 Weigt 60 kg Dimensions 800 x 450 x 500 Part Name Support Material GG 20 Weigt 21 kg Dimensions 450 x 300 x 200
22 Part Name Compressor Cylinder Head Material GG 25 Weigt 8 kg Dimensions 400 x 200 x 100 Part Name Reduction Housing Material GGG 50 Weigt 9 kg Dimensions 300 x 200 x 140 Part Name Gearbox Cover Material GG 25 Weigt 125 kg Dimensions 1200 x 1000 x 450 Part Name Gearbox Body & Cover Material GG 20 Weigt 16 kg 8 kg Dimensions 250 x 200 x 410 Part Name 90 Shaft Cover Material GG 40 Weigt 45 kg Dimensions 700 x 600 x 500 Part Name Air Valve Housing Material GG 25 Weigt 12 kg Dimensions 250 x 400 x 120
23 Pump & Valve Industry Part Name Water Pump Body Material GG 25 Weigt 32 kg Dimensions 700 x 600 x 240 Part Name Cooling Compressor Body Material GGG 25 Weigt 120 kg Dimensions 1000 x 1000 x 650 Part Name Impeller Material GG 25 Weigt 15 kg Dimensions Ø 300 Part Name Pipe Coupling Material GGG 45 Weigt 32 kg Dimensions DN 300 Part Name Pump Casing Material GG 25 Weigt 70 kg Dimensions 553 x 620 x 220 Part Name Material Weigt Dimensions
24 Part Name Valve Body Material GGG 40 Weigt 250 kg Dimensions DN 700 Part Name Actuator Housing Material GGG 50 Weigt 590 kg Dimensions 700 x 500 x 550 Part Name Impeller Material GG 25 Weigt 15 kg Dimensions Ø 300 Part Name Tapping Saddle Material GGG 40 Weigt 45 kg Dimensions 500 x 225 x 180 Part Name Adaptor Body Material GG G 40 Weigt 8 kg Dimensions DN 150 Part Name Slide Clamp Material GGG 40 Weigt 10 kg Dimensions 250 x 100 x 150
25 Agricultural Machinery Industry Part Name Gearbox Cover Material GG 25 Weigt 28 kg Dimensions 500 x 350 x 180 Part Name Bracket Material GGG 40 Weigt 12 kg 15 kg Dimensions 450 x 350 x 200 Part Name Shaft Cover Material GGG 50 Weigt 9 kg Dimensions 300 x 200 x 140 Part Name Cover Material GGG 50 Weigt 18 kg Dimensions 300 x 200 x 240 Part Name Shaft Extension Material GGG 40 Weigt 40 kg Dimensions 450 x Part Name Loading Arm Material GGG 40 Weigt 14 kg Dimensions 400 x 200 x 150
26 Civil Engineering Industry Part Name Tube Fittings Material GGG 40 Weigt 0,5 kg 6 kg Dimensions ¾ -2 Part Name Manhole and Cover Material GG20 - GGG 40 Weigt 11 kg 18 kg Dimensions 400 x 400 x 400
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