1. By
D.Dinesh
D.Dhanya Prasad
(PSG POLYTECHNIC COLLEGE)
GREEN
MANUFACTURING
IN FOUNDRIES

2. INTRODUCTIO
N:
 Green technology encompasses a large body of
concepts whose definition may vary by group or
industry. Green technology is broadly defined as “The
technology that finds smarter ways to use our finite
natural resources, both in manufacturing materials
and in the energy resources used to manipulate
them”.
 Green technology can include energy material and the
waste reductions in manufacturing processes, and the
use of alternative manufacturing technologies with the
least, the least impact in the human health, the earth
and its natural resources.

3. FIRST STEP:
 The first step for green manufacturing is to greening the
industry.
 Many of us believe the idea that simply recycling our region’s
available scrap and sand makes us a green industry and we need not
go further, but doing such process we can make only a clean
industry not a green industry.
 To make our company green industry and also the pioneers in green
manufacturing a top management support is required to establish it
as a priority, right along with all other key matrices such as safety,
quality and probability. A management culture needs to be
established to foster the goal of being green and sustainable.

4. STARTING THE PROCESS:
 Now it time to keep our profit oriented company aside to make a
green and profit oriented company.
 In green manufacturing process we should not forget one thing that
every area in the foundry operation is a fertile ground for green
savings. To make a foundry green the following are some of the
processes:
 Energy savings.
 Core systems.
 Pollution control.

5. ENERGY SAVINGS:
 In foundry industry the energy savings comes in four section.
 Melting.
 Sand reclamation.
 Machining.
 Lab

6. MELTING:
 The industry’s major energy is used in the melting section.
DISADVANTAGE ADVANTAGE
Sheared scraps are used in most
foundry in which it contains lots of
rust and other non metallic particles
that consumes more than 1.7-2
times of the energy to melt.
Using of shredded scraps(contains
no non-metallic particles) can save
Upto 15-20% of the energy that
takes to melt.

7.  Using of baghouse heat recovery system many prevent the wastage of
heat that is produced in cupola and also in induction furnaces and use it
for later uses. The installation charges for this baghouse heat recovery
system may take $150.000 and also prevent a loss of about
$144.000/year to the industry.
 According to nature saving it is equal to 153 cars removed from the road
and also about 8 acres of forest preserved.
Bag house recovery system

8. SAND
RECLAMATION:
 The most important section in the foundry industry in which 15%
of the industries energy is used:
Thermal sand reclaimer
DISADVANTAGE ADVANTAGE
Many of the foundries don’t have a
sand reclamation plant and most
industries only have a sand
reclamation plant that is fully
electrically controlled.
Using of thermal sand reclaimer
and pneumatic/ mechanical sand
reclaimer saves about 3% of the
energy used in this section.

9. MACHINING:
 Machining is the most important job in the foundry which deals
with customer satisfaction.
High efficiency motor Pneumatic controlled grinder
DISADVANTAGE ADVANTAGE
The motors at present used in
bench grinding and other
machining tools consumes more
electrical energy.
Instead using high efficiency
motors and ultra-high efficiency
motors can save Upto 2-5% of the
operating energy. And also the
usage of pneumatic controlled
machines also saves electrical
energy and cost.

10. LAB:
 The lab in foundries does not consume more energy but to make a
foundry green each and every steps are clearly to be noted and
done.
CFL Bulbs Advanced spectrometer
DISDAVANTAGE ADVANTAGE
This is the major problem around the
world the usage of incandescent bulb and
usage of old model electrical testing
machines also consume more energy.
Instead usage of CFL light bulbs and
replacing old with advanced machines
saves about 2% of electrical energy and
also by using transparent roofing sheets
may also avoid day lighting.

11. CORE RECLAMATION
SYSTEMS:
 To make a foundry green manufacturing it mainly concerns with
sand reclamation. Most of the sand used in the moulding is
reclaimed but the core sand is not reclaimed.
DIADVANTAGE ADVANTAGE
In INDIA most of the foundries
don’t use core reclamation
techniques which makes them to
stay behind as a non green foundry
and non green manufacturing
foundry.
The installation of the polygon sieve
core reclamation plant may save the
core sand to be dumped outside and
also making a foundry green
manufacturing industry.

12. ENERGY DISTRIBUTION
CHART
40%
15%
20%
5%
5%
5%
10%
Melting
Sand Reclamation
Machining
Lab
Core Making
Pouring
Knock Out

13. POLLUTION CONTROL:
 This is the main concept that has to be done to make foundry green
and a green manufacturing unit. This involves upgrading the
following processes:
 Core making.
 Moulding.
 Melting.
 Pouring.
 Knock out and Shot blasting
 Machining.

14. CORE MAKING:
 This is the base section of the foundries and the second step after
energy saving for green manufacturing in foundries.
DISADVANTAGE ADVANTAGE
During making of core lots of sand
get spilled down and also wastage of
the sand takes place. Due to this the
core section in foundries get dirty
which fails to make a foundry a
non-green manufacturing unit.
By using the automatic core
shooting machine the spillage of
sand is reduced and also it makes a
green environment and a green
manufacturing system.

15. THE AUTOMATIC CORE MAKING
MACHINE AND CORE SHOOTER

16. MOULDING:
 In this section, two types of pollution have to be controlled to
make a foundry green manufacturing, they are noise pollution and
air pollution.
DISADVANTAGE ADVANTAGE
Many industries only have the
squeeze jolting machine which
makes more noise during the sand
ramming and also many sand get
squeezed out of the mould box
which creates a polluted
environment.
By the replacing the machines with
fully automatic machine the noise
pollution and the air pollution will
be brought under the control. By
making the moulding automatic the
mould surface and the mould
hardness will be increased.

17. FULLY AUTOMATIC
MOULDING MACHINE

18. MELTING:
 In this section the pollution depends on the furnaces used.
DISADVANTAGE ADVANTAGE
Many of the small scale foundries
in INDIA use cupola type furnace
which releases more amount of
carbon content in the atmosphere
and also usage of rotary furnaces
too create more pollution during
initial process.
By replacing such type of furnaces
with induction furnaces may
reduce pollution in foundries and
also by using minute dust
extraction towers the pollution
can brought under control.

19. HIGH TOWER DUST
EXTRACTION SYSTEM

20. POURING:
 The pollution in pouring section is always a huge problem to the
labours.
DISADVANTAGE ADVANTAGE
The pollution is caused when the
hot molten metal reacts with the
dust particles that are present in
the molded sand and also due to
manual pouring of the molten
metal.
This pollution can be brought
under control by the use of auto
pourer machine and also by
separating the dust particles from
the sand that is used and also
avoiding the green sand process.

21. THE AUTO POURING
MACHINE

22. KNOCK OUT AND SHOT
BLASTING:
 Every industry in INDIA including small scale industry use a knock
out machine and a shot blasting machine.
DISADVANTAGE ADVANTAGE
Even though the foundries have a
machine many of the foundries use
a knock out machine that don’t
have closed cover around them
which increases the pollution and an
automatic shot blasting machine.
To reduce the pollution in knock out
section the only way is to have a
knock out machine with closed
cover and larger sieve size and in
shot blasting an automatic machine
reduces the time.

23. A TUNNEL BASED CLOSED
KNOCK OUT MACHINE

24. AN AUTOMATIC SHOT
BLASTING ROLLER MACHINE

25. MACHINING:
 The main pollution in foundries is noise that makes the workers
strain and also leading to deafness.
DISADVANTAGE ADVANTAGE
During the machining operation
the usage of old motors and
usage of old machines makes
large noise that creates
pollution.
This can be brought under
control by using pneumatic
controlled machines and also by
placing sound absorbers near to
them.

26. ADVANTAGES:
 The pollution can be brought under control.
 The yield of the foundry can be increased.
 Good and sound castings can be produced due to automatic
machines used.
 A green industry can be achieved using this techniques.
 A good environment which doesn’t harm the nature and living
beings can be created.
 Energy can be saved to use in future.

27. DISADVANTAGES:
 The installation of the machines needs more investment.
 Requirement of technically skilled labours are necessary, this may
also lead to unemployment of uneducated labours.
 The maintenance of the machines are compulsory and it takes
more cost.

28. ANY QUERIES ?..

29. LET’S REMEMBER:
PLANT TREES & SAVE ENERGY