Ultraseal’s new R-FL-Duplex+ machine sparks interest in casting impregnation

Ultraseal International attracted great interest in its R-FL-Duplex+ machine which is transforming casting impregnation with its two-stage process and small factory footprint at GIFA 2015.

Visitors were impressed with the flexibility of the modular machine that can be scaled up to achieve a throughput of 45 cycles an hour simply by adding extra modules to suit requirements.

Fully automated, the R-FL-Duplex+ eliminates all manual handling of parts and therefore requires no operators, making the casting impregnation process easier than ever before.

Simple to integrate into a modern production line, it is especially suited to single part processing of components such as automotive engine blocks, but multi-part processing is also possible as the machine can work with trays if necessary.

The machine was on show at GIFA 2015 where visitors learned how it built on Ultraseal’s impressive pedigree of innovation in recycling sealant technology that uses less chemicals, less water and produces less waste-water than conventional casting impregnation processes.

Stephen Hynes, Marketing Director of Ultraseal International, said: “The R-FL-Duplex+ got at GIFA is a truly transformational machine and it wasn’t surprising that visitors were keen to hear about all of its advantages.

“It combines our acknowledged leadership in recycling sealant technology with our substantial experience in designing fully automated casting impregnation equipment to give unsurpassed results.

“Many manufacturers now use casting impregnation with Rexeal 100™ and Ultraseal MX2™ as a routine quality enhancement and the R-FL-Duplex+  

has just made the process even quicker without sacrificing any of the quality of finished parts that customers have come to expect from Ultraseal.

”We are very excited about this innovation and so are our customers.”

Ultraseal International is living up to its global reputation for being at the forefront of casting impregnation technology with its new two-stage process that was unveiled at the show in Dusseldorf, Germany.

Casting impregnation is an important post-casting process for diecasters because it offers a reliable and permanent solution to the problem of porosity – microscopic holes – in cast metal parts that can cause a part to leak.

Traditionally, impregnation is carried out in three stages: firstly, parts are placed in an autoclave and a vacuum applied that will draw air out of any porosity before a liquid sealant is introduced; secondly, parts are washed in a cold wash cycle and finally they are moved to the ‘hot cure tank’ where the heat transforms the liquid within the porosity into a solid, flexible plastic.

Scientists at Ultraseal International have revolutionised the design and eliminated one of the three stages of the Casting Impregnation process entirely without in any way compromising the quality of impregnation process.

By eliminating the cold wash stage of the process, and recycling sealant and water from the hot cure stage, the R-FL-Duplex+, produces zero aqueous effluent and requires no downtime for routine water changes.

Kevin Siviter, Technical Manager of Ultraseal International, explained: “The R-FL-Duplexhas a new hot cure recycling process. There is no wash station – parts go straight from the autoclave to the hot cure tank. It is a continuous, real-time process that is very robust and offers all the advantages of our recycling sealant technology.

“Customers will get the same impregnation quality as they would achieve with a three-module machine in regard to sealability and cleanliness but the machine would take up one-third less space, less energy is required to run it and it has increased production throughput.”

Ultraseal has led the field for decades and is once again transforming the face of vacuum impregnation, with all of its innovative chemistry carried out at its headquarters in the UK.

It exhibited at GIFA alongside Sterr & Eder Industrieservice GmbH, of Velden, near Munich, the renowned German jobshop which it acquired in 2013, and Lubrolene water-free die release agents, with which it has a strategic European partnership.

The company has a global reach – exporting to more than 35 countries and with Joint Ventures in China and India, an operation in the United States, an office in Japan and a network of 22 agents/distributors as well as a number of associated jobshops around the world.

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