The Industry 4.

0 Foundry
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 Our Vision
„„Our competitive lead in technology
optimizes our customers‘ production
process.

Our Mission
„„We produce components, systems
and equipment for the optimization
of manufacturing processes.

„„We want to understand the

processes used by our customers.

„„We are a strongly diversified

global player.

„„We aim for the top position in all

markets we participate.

„„We are a family based enterprise

with tradition and values.

„„We include our employees in the

decision making processes.

„„We strive for a reasonable return on

and increase of the equity capital.

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 Kurtz Ersa SMART FOUNDRY
Shaping the future together!
Since 1852, Hasloch has been the With 120 highly-qualified staff, Kurtz In both our external and internal deal-
site of an iron foundry – an important Eisenguss GmbH & Co. KG, as a 100 % ings we place emphasis on an open
core competence in the owner-run subsidiary of the Kurtz Ersa Corpo- and respectful dialogue which we wish
family company Kurtz Ersa which can ration, operates what is probably the to continue promoting and expanding
look back on a tradition spanning over world’s most modern hand moulding with you, our customers, suppliers
235 years. foundry: sustainable, future-proof, ef- and partners. Because even in the era
ficient. Only in this way can the most of Iron Casting 4.0, communication
“Our technological lead optimises wide-ranging of complex customer and expertise are still the basis for
the manufacturing processes of our requirements be catered into the success. Good luck!
customers.” In order to live up to this future. Something we do at a unique
vision in the future too, Kurtz Ersa technological level, inter alia, with the Your Graziano Sammati
Graziano Sammati has invested in the SMART FOUNDRY, newly-designed material flow, com- Managing Director
Managing Director and thus impressively pledged its puter-aided logistics system, clocked
Kurtz Eisenguss GmbH & Co. KG
commitment to Hasloch as a business line production and SAP-integrated
location. business processes.

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 Separate cast house, detached from other Automatic transport logistics with System-controlled cooling house with System-controlled pouring hall for
production processes unmanned floor conveyors ventilation and exhaust air extraction controlled pouring with optimised sand
system and heat recovery regeneration

Kurtz Ersa SMART FOUNDRY

The most modern foundry for the most successful companies
With modern, future-proof technolo- We cooperate with well-known cus- Customer benefits of
gy, Kurtz Eisenguss GmbH & Co. KG is tomers from a wide range of sectors: SMART FOUNDRY:
committed to Germany as a business from sophisticated mechanical
location. This decision is important engineering to drive engineering, con- „„SAP integration of customers and
for many of our customers too, struction site equipment and building business partners in the business
meaning as it does that high-quality material machines, printing machines, processes
cast iron continues to be availa- press manufacture, power engineer- „„Increased delivery reliability for
ble and accessible in the heart of ing, vehicle construction, medical greater planning dependability
Europe – with considerably increased technology, manufacture of internal „„Environmental protection secured
productivity and quality and with en- combustion engines, railway vehicle long-term, e.g. with heat recovery
vironmental technology which offers manufacturing and wind turbine con- systems for exhaust air from dust
long-term security for the future. Are struction and vacuum engineering. extraction plants
you ready for the iron casting of the
21st century?

Extract
from our
client list

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 Mechanical engineering Shipbuilding Railway vehicle manufacturing Wind turbine construction

Kurtz Ersa SMART FOUNDRY

20,000 t of finished castings ... and still rising!
Our product range is very extensive The use of spectral analysis, thermal
– from gear parts such as planetary analysis, ultrasound, hardness and
carriers, torque plates and casings to crack testing as well as dye penetra- Machine base Casing
machine parts such as machine beds tion processes and metallographic
or machine bases and pressure-tight and metallurgical material tests
parts such as pump housings or, for constantly ensure the highest quality Key Data SMART FOUNDRY
example, cable drums which are used for our customers’ cast iron parts.
in hoisting technology. ■ Max. part dimensions: 3,000 mm x 5,000 mm
■ Part weights: 150 kg to 8,000 kg
The process steps in the parts manu-
■ Materials: EN-GJL-150 to -300
facturing are permanently supervised
EN-GJS-400 to -800
and documented by our quality man-
Solid solution strengthened GJS (high Si alloy)
agement system and are subject to
DIN EN 1564 compliant ADI materials
constant monitoring, culminating in
additional non-destructive ultrasonic ■ Capacity: 20,000 tonnes per year
flaw detection.

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 Unmanned
transport Unmanned
Smart Smart
system (FTS) transport
System Customer Foundry Processes Foundry Customer
vehicle
ERP system Master ERP system
(FTF)
computer

Manufacturer Any SAP SAP SAP Human SAP Any

Panel
Interface EDI IDOCs Records IDOCs DI
Buzzer

Production Transport Orders

orders Schedules
Content Orders orders Feedback Packing slips
Transport Confirmation
requirements Confirmation Invoices

All the processes are centrally monitored at the control station

= Logistics system

Kurtz Ersa SMART FOUNDRY

Automated logistics processes – Industry 4.0 live
Visualisation of the
The SMART FOUNDRY with the The result: simple handling of complex
individual stations
SAP-aided production concept, par- manufacturing processes, continuous of the unmanned
celled production areas and the un- monitoring of the systems and man- transport system
manned, universally mobile transport ufacturing processes via the central
system permits a flexible process control station, ideal processing
chain, in which manual manufacturing times. If you too value these factors,
steps and the automated logistics we really should talk!
system can be ideally combined.
Work orders are
electronically sent
to the production
line. Display of the
incoming and out-
going work orders
at each workplace

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 Intensive and
separate extraction
in the magnesium
treatment

Kurtz Ersa SMART FOUNDRY

The new standard when it comes to the environment
With separated production processes, The SMART FOUNDRY has made it
the climate in the individual depart- possible to double productivity in man-
ments is significantly improved as the ufacturing and at the same time vastly
emissions can be much better extract- improve the quality of the workplace:
ed when similar activities are grouped The harmful effects on the health of Latest heat
recovery plant
in one place. staff have been considerably reduced,
the climatic conditions improved and
The unmanned transport systems work the crowding and heat stress mini-
electrically and therefore emission-free mised.
and meet a high safety standard –
therefore offering clear benefits com- In short: SMART FOUNDRY is geared
pared to manually operated vehicles. to top products for our customers
and ideal working conditions for our
Each manufacturing segment can foundrymen.
draw on the necessary quantity of raw
materials and supplies, cores, casting
iron and fresh air – all without manual
The most modern
labour. filter systems for
air quality control

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 Certified quality in the Kurtz Ersa Corporation

Kurtz Ersa SMART FOUNDRY

Know-how – quality – adherence to delivery dates
In the corporate guidelines of the all-encompassing quality management At Kurtz Ersa, all the processes are
Kurtz Ersa Corporation, product quality system based on the DIN EN ISO 9001 : defined and subject to constant, con- Certifications
is defined as a significant component 2008 certification. tinuous and transparent performance „„TÜV Certification
of the company policy. Our products measurement systems for: Pressure Equipment Directive
impress with high quality. Only in this Furthermore, our primary focus is on 97/23/EG
way can we be a reliable partner for customer satisfaction. This involves „„Production „„Germanischer Lloyd
the customer. Quality assurance is product quality, adherence to delivery „„Quality „„Lloyd´s Register
therefore a central issue in all the dates, appropriate product prices, „„Processes
„„Energy Management
companies. communication, competence and „„Customer satisfaction ISO 50001:2004
reliability. We therefore maintain our „„Markets
„„Environmental Management
Through continuous improvement own modelmaking which can offer you „„Costs ISO 14001:2004
processes, we constantly work on en- support in the design of your cast iron „„Sales
„„Health and Safety Management
hancing the internal cooperation, the parts. This is facilitated by modern OHSAS 18001
products, the processes and the effi- CAD programmes. The simulation of
„„Quality Management
ciency. The implementation of these casting and solidification processes is DIN EN ISO 9001:2008
quality principles is achieved, among also among the service we can offer
„„ABS Certification
other things through our integrated, you.

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 Mono-material feedstock Thermal analysis of the molten mass Temperature monitoring of the molten mass Constant monitoring of the furnace and the
refractory material

Kurtz Ersa SMART FOUNDRY

The meltshop – leaving nothing to chance
With our casting experience and Constant monitoring of the processes
expertise, we produce more than 60 through spectral analysis, thermal
different iron casting materials. Our analysis and constant temperature
feedstock is stored dry and clean in monitoring ensures the highest
mono-grade form, and is fed into the quality.
furnaces through chutes.

Recasting the
magnesium-treated
molten mass into
the casting ladle

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 Kurtz Ersa SMART FOUNDRY
Hand moulding – ready-to-pour moulds at a system-controlled pace
System-controlled hand-moulding 5,000 x 3,500 mm can be used. In the
in forms clocked in accordance with next process step, the moulds are
the pull-push principle. Thanks to the prepared for casting. The associated
use of a mobile cold resin-furan sand cores are automatically supplied as
mixer, box sizes of 700 x 700 mm to well.

Staff at work
filling the mould
for a machine base.
Here, compacting
the sand and
applying the
casting system
are particularly
important.

Unmanned trans-
port system at
work transporting
the moulds to the
next process step

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 Kurtz Ersa SMART FOUNDRY
Experienced foundrymen,
ideal working conditions and
a new cast house

In the new foundry, a new ventilation

and exhaust air extraction system
creates ideal workplace conditions.
The casting process is separated
from the other production process-
es and housed in a separate hall.
As a result of the management and
clocking of production, highest-quali-
ty melts are punctually produced and
made available.

Using chain hoists, the melt is cast

via transport ladles from safe posi-
tions, taking analyses and tempera-
ture into account.

Highly qualified
staff casting a
6 t planetary carrier

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 Part treatment Priming in the company’s own paint shop

Kurtz Ersa SMART FOUNDRY

Controlled cooling and controlled removal from the mould
Following the system-controlled In the following processes, the cast
cooling of the cast iron parts in the iron parts are blasted, cleaned and
cooling hall, the mould boxes are subjected to different test processes
automatically transported to the depending on customer wishes. They
unpacking hall. This is equipped with are then primed in the company’s
a ventilation and waste air extrac- own paint shop, before moving to the
tion system. Thanks to the attached dispatch hall, ready for delivery or
regeneration plant and the lead- collection.
ing-edge technology, the removal of
dust from used sand is significantly
better, and the sand values are
considerably improved. A development
which is equally positive for staff
and the environment and which also Clean, dry
means security for the future. and fast dispatch

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 Metal Components in the Kurtz Ersa Corporation
A consistent supplier concept for your requirements
The large variety of products man- We offer our customers the certain- Kurtz Ersa’s business areas have well as software generation. At Kurtz
ufactured, production technologies ty that, with Kurtz Ersa, they have grown historically. Due to our long Ersa, production technologies are a
in use and areas of business mark chosen an internationally oriented corporate tradition, we are accus- dynamic process.
Kurtz Ersa as a corporation with partner who understands the needs tomed to early develop and integrate
large technological potential and a and practices of the global market. new technologies, new markets We are close to our customers. Our
multitude of possibilities for raising and new production methods. The extensive product range covers most
synergy effects. It is the common We have repeatedly set new stand- processes used by Kurtz Ersa include, of our customers’ requirements.
goal of the group’s members to play a ards in technology with our products. amongst others, casting, welding In addition, we offer equipment
major role in their market and to be a Our willingness to take new venues and soldering, cutting and forming, designed and manufactured to a cus-
technologically leading manufacturer has enabled us to meet specific machining operations, galvanic- and tomer’s specific requirements.
in their fields. requests of our customers, but it also surface treatment, heat treatment,
enables us to optimise our perfor- measuring- and test technology as
mance and competitiveness.

ISO 9001
Information quality
Castings Machining security management
system

„„Design services „„CNC drilling, milling, turning ISO 14001

Internal
environmental
„„Grey cast-iron „„Planing control systems
Kurtz Ersa management

„„Nodular cast iron „„Measuring Integrated

management
system OHSAS 18001
Rightfully, our customers expect that we take Business workers’
Surface treatment Sheet metal technology excellence safety / health
the extra step, and that is why we have an un- protection

„„Powder coating „„Sheet metal technology derstanding of quality not permitting any com-
ISO 50001 Risk
„„Painting „„Design services promises. Permanently monitoring our customers’ energy management
management
„„Electroplating „„Laser cutting expectations and matching these to our own strate-
„„Laser marking „„Punching/nibbling gic objectives defines our target. To achieve our target,
„„Screen printing „„Bending we build on integrated quality management as our guiding
„„Welded constructions principle, on comprehensive internal and external certifica-
„„Assembly tions as well as on competent, quality-conscious employees.

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 The root of our
company:
The historical
forge hammer mill
in Hasloch is still
operating; today it
is an industrial
landmark.

Fine Traditions and a Bright Future

Sustainability is an integral part of our corporate culture
Our first production plant – a forge Sustainability is an integral part of the sustainability aspect into this In the development cycle of our own
hammer mill, which started to produce Kurtz Ersa’s corporate culture, in our management system, thereby creating products, the improvement poten-
in 1779 – was operated with water product development and manufac- the basis so that all our employees are tial regarding the use of resources
power. This historical industrial land- turing processes. In this way we want included as well in their daily actions. is defined already in the equipment
mark is maintained as a visual symbol to contribute our share to sustainably specification.
of a sustainable corporate develop- improve the living conditions on our The sustainability aspect in our own
ment. planet Earth. diverse manufacturing processes is At Kurtz Ersa, the concept of sustain-
closely monitored with improvements ability is taken seriously.
The base for the processes’ systemat- being mandated regularly. Internal and
ic control is our management system. external audits ensure the success of
For this reason, we have incorporated this process.

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 283 634 - 0315 | subject to changes | © Kurtz Eisenguss GmbH & Co. KG
Kurtz Eisenguss GmbH & Co. KG Tel. +49 9342 805-0
Eisenhammer Fax +49 9342 805-179
97907 Hasloch/Main smart-foundry@kurtzersa.de
Germany www.kurtzersa.de
www.smart-foundry.de

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