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www.mmcpublications.co.uk DIECASTING | 47

From the scrap yard to the

production plant

Bühler Die Casting offers a customised retrofitting programme in collaboration with its Italian partner, Brescia Presse for

diecasting machines of all sizes and makes. The following contribution describes two neglected Evolution 180D machines

that were completely overhauled and made ready for production in Europe and Asia.

Neither of the neglected Bühler Evolution 180 D
diecasting machines (18000 KN locking force) had

been used for quite some time. The original buyer
miscalculated his market opportunities and had
built up more capacity than could be used.
The two machines were only used as ‘spare parts

warehouses’ and consequently, were in poor
condition when purchased by a globally active
foundry company at reasonable terms and
conditions. The internationally successful foundry

was in urgent need of increasing production
capacities at its factories in Europe and Asia above
and beyond its existing Bühler machinery and
found what it was looking for in the US second-

hand market.

Sticking points
Two diecasting machines – in a dilapidated machines overhauled and upgraded at BP in accepted without any objections and to the

condition in a warehouse located somewhere in the Brescia.
satisfaction of the customer and authorities. The
expanses of the USA – had to be totally overhauled, At the headquarters of Bühler Die Casting in icing on the cake for the customer was when he
assembled at two different locations in Europe and Uzwil, Switzerland, the replacement country- was handed all customer documentation in his
Asia and started up again. This was an open and specific drive assemblies were built and control native language. This is not something normally

shut case for the Bühler-Brescia Presse duo!
systems programmed. Disassembly in Canada and taken for granted in the overhaul business outside
the various shipments were organised through the Europe.
worldwide Bühler network.

Weekly reports
This meticulous planning proved to be the key
for the quick and successful overhaul of the two
Evolution 180D machines. When the machines

arrived at Brescia Presse in Italy, they were
completely disassembled, cleaned and inspected in
detail in terms of their condition and reusability. At
that point, the company was able to put together a

definitive quotation for the overhaul, to be
discussed on site with the customer and to be
adjusted to meet final requirements.
Overhaul of the individual parts went according When a joint project team got to work on the After successful acceptance, the two diecasting

to plan. Wear parts were replaced and repairs were planning process, certain sticking points soon machines were disassembled again and prepared
made where necessary and feasible. The customer became evident. For one thing, the second-hand for shipping. The machines were reassembled at
was kept informed of progress through weekly equipment, spare parts and later, the overhauled their production locations by the same specialists
reports and logs. Soon, it was possible to start diecasting machines would have to be shipped who performed the overhaul work. This

reassembling the two diecasting machines. With across great distances, over land and water, to the contributed to the fast and reliable resumption of
the equipment delivered from Uzwil, ie the original proper destination and on time. Then, one of the production.
Bühler spare parts, the replacement drive two machines would have to be adjusted to meet
assemblies and control systems that were converted the specific technical requirements (voltage and Customised overhaul

to Datanet, the two Bühler diecasting machines frequency, as well as safety regulations). In the end, Just a few months after being shipped to faraway
were put back together step-by-step at one of the customer requested a partial upgrade to locations, the two completely overhauled diecasting
Brescia Presse’s production plants, turning out to increase productivity. This included, for example, machines are once again being used for
be just about as good as new.
using a simultaneous hydraulic system to allow the manufacture. Thanks to the retrofit teams from
die and the core to be moved at the same time, Bühler and Brescia Presse, two practically new

Acceptance in Brescia
which substantially reduces the cycle time.
Bühler machines were created. They meet the
After final assembly of the Evolution 180D company’s latest standards in every way. The
intended for use in Asia, a dry run of the two Planning with military precision
availability of spare parts is also guaranteed and as
diecasting machines was conducted in the The planning work resulted in a meticulous flow ‘original’ Bühler machines, they are part of the

customer’s presence and in front of the inspection chart created with military precision, with a focus company’s network of local service centres
authorities of the country of destination. The test on cost optimisation and including a division of worldwide.
run went flawlessly and the equipment was
labour. The plan was to have both diecasting
www.buhlergroup.com

Cast Metal & Diecasting Times January/February 2014