Production Plants

From producing casting cores to inspections: our know-how is at your service at two production plants.

FA foundry activities are carried out at two operational plants: the main one in Santa Maria degli Angeli, and another in Cannara, both in the province of Perugia.

The Santa Maria degli Angeli plant, which stretches across an area of over 30,000 m2 (11,000 m2 of which are indoors), is where we carry out the main production process activities, ranging from the production and finishing of casting cores destined for the foundry, to melting and moulding the materials, and finally casting and blasting.

One distinctive feature of which we are particularly proud is our core production, which allows us to make 100% of the cores we need through both hot and cold processes.

In recent years, we have increased our production capacity and started the process of automating production, activating 4 robots. The 5th will go into operation by the start of 2022.

We are able to produce 65 tonnes of core every day through the cold process, and four tonnes through the hot process, thanks to our fleet of machines:

  • 13 cold-box core-shooters, with capacities varying from 7 to 60 litres;
  • 5 hot-box core-shooters, with capacities varying from 5 to 18 litres;
  • A centralised system for the preparation and distribution of sand;
  • 1 tunnel furnace for drying the cores after painting;
  • 2 automated centres for core assembly;
  • 5 robots.
The smelting department allows us to be extremely flexible in producing different materials, as we are able to cast up to 5 completely different alloys during the same shift. Our smelting equipment consists of:
  • 2 rotary furnaces, with a capacity of 20 tonnes each;
  • 6 electric furnaces (three furnaces with a capacity of 28 tonnes each, the other three of 7, 2 and 1 tonnes respectively);
  • 2 furnaces with a capacity of 4 tonnes each for automatic casting.
Batterie di Sparaanime Fonderia Assisi Fa Group
Attività di scorifica forni elettrici Fonderia Assisi

The smelting department allows us to be extremely flexible in producing different materials, as we are able to cast up to 5 completely different alloys during the same shift.

Our smelting equipment consists of:

  • 2 rotary furnaces, with a capacity of 20 tonnes each;
  • 6 electric furnaces (three furnaces with a capacity of 28 tonnes each, the other three of 7, 2 and 1 tonnes respectively);
  • 2 furnaces with a capacity of 4 tonnes each for automatic casting.

Thanks to these furnaces, we are able to achieve a high production capacity and produce cast iron and steel through different metallurgy techniques simultaneously:

  • 200 tonnes molten cast iron/day;
  • 100 tonnes of iron castings produced/day;
  • 23 tonnes molten stainless steel/day;
  • ~5 tonnes of steel castings produced/day.

The cast-iron moulding department is notable for allowing equipment to be changed out without downtime, so as to have no impact on line efficiency.

 

It consists of the following:

  • Georg Fischer Disa automatic line with a capacity of 180 moulding boxes/h;
  • Moulding box dimensions: 900x700x300+300 mm;
  • Foundry sand regeneration system: 2 speed mullers with a capacity of 70 tonnes/h; 2 fluid-bed coolers; 1 polygonal screen; a computerised system for additive and humidity control;
  • Robotic system for handling and casting shells for the steel line;
  • A continuous blasting machine with metal mesh conveyor.

Production capacity:

 

  • 2,800 moulding boxes/day for cast iron;
  • 500 shells/day for steel.
Reparto formatura Fonderia Assisi Fa Group
Centro di lavoro per Lavorazione Meccanica Fa Group

The Cannara plant (just 6 km away from the main plant, with a total surface area of over 165,000 m2, including 11,000 m2 indoors) is where we concentrate on the final steps of finishing, machining, assembly and inspection. Here, we can count on a fleet of machinery consisting of:

  • 2 tumblast blasting machines;
  • 1 tunnel blasting machines;
  • 2 manual internal blasting machines;
  • 2 robotic internal blasting machines;
  • 4 CNC MAUS machines for automatic deburring;
  • 8 CNC KOYAMA machines for automatic deburring;
  • 3 treatment furnaces;
  • 4 conveyor belts for the final visual inspection;
  • 1 automated system for deburring by shearing;
  • 7 lathes;
  • 1 Swiss-type lathe;
  • 9 CNC Centres (4-axis);
  • 1 cleaner;
  • 5 leak test benches;
  • 6 assembly benches;
  • 1 laser engraving bench;
  • 1 measuring room with Hexagon and Zeiss measuring machines.