The redesign of the ATIK METAL foundry plant in Aliaga, Turkey,

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Foundry Corporate News Topic Patternmaking, mouldmaking and tooling & Rapid Prototyping, rapid tooling Topic Plant Technology, Equipment

19. June 2024

"It all starts with a dream..." -

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The redesign of the ATIK METAL foundry plant in Aliaga, Turkey, is one of the largest orders in the 30-year history of VHV Anlagenbau GmbH. As a renowned manufacturer of belt conveyor systems and specialist in steep conveyor technology, VHV was selected to supply customized solutions of the highest quality for this major project.

Cooperation and partnership

When selecting suppliers, owner and managing director Mehmet Atik focused on the highest quality and smooth interfaces. The cooperation with companies such as VHV Anlagenbau GmbH, Eirich official | Maschinenfabrik Gustav Eirich GmbH & Co KG , Heinrich Wagner Sinto Maschinenfabrik GmbH and JOEST group was decisive for the success of the project. Thanks to the long-standing partnership and trusting cooperation, innovative solutions were developed and implemented.

Project scope and implementation

The project comprised the development and implementation of a state-of-the-art foundry system that met the market requirements for ever larger castings. Close coordination and quick decision-making in team meetings led to optimizations in the project process. The involvement of Mehmet Atik in the meetings enabled immediate clarification and the rapid implementation of suggestions for improvement.

Technical details and equipment

The foundry plant has impressive dimensions, with factory halls 350 metres long, 120 metres wide and a 24 metre high compact plant in the central preparation area. The plant is equipped with state-of-the-art technology, including 4 Eirich mixers in the Evactherm® system, the HWS 5 and HWS 6 moulding plants and 4 electric furnaces for melting molten iron.

Another important aspect is the sustainability of the project, as a large proportion of the material melted down is reused from scrapped ships.

With the HWS6, ATIK METAL may not have quite the largest moulding boxes in Turkey (2.38 m² instead of 2.44 m²), but with 80 moulds/h it has achieved four times the cycle rate of others.

VHV supplied a variety of equipment for the project, including new sand bunkers, belt conveyors for used sand and finished sand, as well as scraper plows and dedusting connections. Among the elements supplied were 76 belt conveyors and a cover belt conveyor GB1000.

In addition, 4 polygon screens, a double molded sand bunker and a bunker for new sand were integrated from VHV production. The largest throughput rates are 360t/h [300m³/h]. The remarkable equipment features also include the partially reversible discharge belts. Another important aspect is the removal of the separated metals via compact belt conveyors in VHV K racks. The new foundry plant has a total output of 120,000 tons of castings per year.

Results and outlook

The successful cooperation of all companies involved has resulted in a project that meets the highest quality and performance standards. The new foundry plant will significantly increase ATIK METAL‘s production capacity and delivery range and consolidate its position as a leading supplier in the industry. VHV Anlagenbau GmbH would like to thank Mehmet Atik and his team for the trustful cooperation and this groundbreaking order.

Future developments

The successful realisation of the ATIK METAL foundry plant demonstrates the potential and possibilities of close cooperation between customers and suppliers. VHV Anlagenbau GmbH has shown here that they are also an absolutely reliable partner for large-scale projects and will continue to develop innovative solutions and supply customised systems to meet the constantly changing requirements of the industry.

Facts, figures and data at a glance