Foundry & Metal Casting

Foundry Bulk Material Handling Solutions

Foundry operations are among the most demanding environments for bulk material handling equipment. Extreme heat, heavy abrasive materials, and continuous production cycles are constants — and the equipment responsible for moving raw materials, compacting molding sand, shaking out castings, and reclaiming used sand has to perform reliably through all of it. Vibration plays a role at virtually every stage of the foundry process, from raw material receiving through final casting and sand reclamation.

Foundry Material Handling Challenges

Foundry materials and processes create handling demands that few other industrial environments face:

Bridging and ratholing of sand, aggregate, and raw materials in bins and hoppers
Incomplete discharge from hoppers and chutes due to material adhesion and compaction
Inconsistent sand density in molds affecting casting quality and structural integrity
Incomplete shakeout — residual sand remaining on castings after knockout
Used sand retaining heat and moisture after casting, changing flow characteristics
Inefficient sand reclamation
Inconsistent charge feeding into cupola and electric furnaces affecting melt quality
Railcar and hopper trailer unloading of sand, coke, and charge materials
Heavy abrasive materials accelerating equipment wear
Extreme operating temperatures requiring high-temperature rated equipment
Manual bin hammering and mold tapping creating safety risks and inconsistent results

Why Foundry Materials Are Difficult to Handle
Foundry operations handle a range of materials under conditions that complicate flow and consistency at every stage:
- Foundry sand must compact uniformly in molds to produce structurally sound castings
- Used sand and aggregate retain heat after casting, altering their flow characteristics as they move through reclamation
- Raw materials including sand, limestone, coke, and metal charge materials vary in particle size, density, and moisture
- Casting shakeout requires controlled, consistent force to separate sand completely without damaging the casting or the mold
- Charge feeding into cupola and electric furnaces must be metered consistently for melt chemistry and furnace efficiency
- Ambient temperatures in foundry environments can exceed 450°F, and standard vibration equipment isn’t built to perform reliably under that kind of thermal stress
Foundry Materials Handled
Our equipment is designed to handle the full range of materials moving through a foundry operation:
- Green sand and chemically bonded molding sand
- Core sand and binders
- Reclaimed and recycled foundry sand
- Limestone and flux materials
- Coke and furnace charge materials
- Metal charge materials and additives
- Refractory materials and ramming mass
- Finished castings during shakeout and transfer
Where Our Products Fit in the Supply Chain

Raw Material Receiving Railcar and hopper trailer unloading of sand, coke, limestone, and metal charge materials. Vibration promotes complete, efficient discharge and reduces turnaround time.

Raw Material Storage Keeping sand, aggregate, and charge materials flowing consistently from bins, hoppers, and silos into downstream processing. Properly sized and positioned vibrators eliminate bridging without damaging storage vessels.

Furnace Charge Feeding Consistent, metered feeding of coke, iron, and limestone into cupola and electric furnaces. Irregular charge feeding affects melt chemistry and furnace efficiency — vibration feeders deliver controlled, repeatable rates.

Sand Preparation & Molding Consistent flow of sand and additives into mullers and mixers before molding. Sand compaction tables ensure uniform mold density for structurally sound castings.

Shakeout & Casting Separation Separating finished castings from molding sand after cooling. Controlled vibration removes residual sand completely without damaging castings.

Sand Reclamation Collecting, cooling, screening, and returning used sand to the sand plant. Vibration conveyors and screens handle hot, abrasive sand efficiently through every step of reclamation.

Finished Casting Handling & Transfer Moving finished castings away from the shakeout area through cooling and on to cleaning and finishing operations.
End Products Supported
Our equipment supports consistent, accurate handling across a range of casting processes and end products:
- Gray iron and ductile iron castings
- Steel castings
- Aluminum and non-ferrous castings
- Investment and shell mold castings
- Sand castings across a wide range of part sizes and configurations
- Core and mold assemblies
Operational Benefits for Foundry Operations
Martin Vibration Systems & Solutions helps foundry operations improve throughput, casting quality, and worker safety across the full production cycle.
- - More consistent sand compaction in molds, reducing casting defects
  - More complete shakeout leading to less residual sand on finished castings
  - Faster, more complete discharge from bins, hoppers, and chutes
  - More consistent charge feeding into cupola and electric furnaces
  - Faster railcar and hopper trailer unloading of sand, coke, and raw materials
  - Improved sand reclamation efficiency resulting in less waste and more reuse
  - Reliable vibration performance in high-temperature environments where standard equipment fails
  - Reduced equipment wear from abrasive materials
  - Reduced manual intervention and lower injury risk

Products Typically Used In This Application

MARTIN^® PKL^® Interval Impactors

Interval impactors generate individual blows similar to a hammer.

Great for spray dryers, pipes and dust collectors
Superb controllability
Reduces noise, energy costs, and bin damage
Available with ATEX certification

Learn More

MARTIN^® NTS™ Non-Impacting Bin Vibrators

This bin vibrator offers low-frequency, high-amplitude energy best suited for larger particle sizes and light bulk densities.

Delivers powerful linear force without impacting
Designed for use with bowl feeders
Available with ATEX certification

Learn More

MARTIN^® NTS™ 80-350 Non-Impacting Linear Vibrators

This non-impacting vibrator provides powerful linear force for moving materials in small bins and hoppers.

Ideal for food, pharmaceutical and chemical applications
Quietest, most energy efficient vibrator on the market
Available with ATEX certification

Learn More

MARTIN^® NTP™ Continuous Impacting Linear Vibrators

This continuous impacting linear vibrator delivers high acceleration for removing sticky materials from vessel surfaces.

Sanitary coating ideal for food or pharmaceutical applications
Comes with cushioning strike plate to reduce stress on vessel walls

Learn More

MARTIN^® NCT™ Rotary Turbine Vibrators

This turbine vibrator delivers efficient rotary vibratory force for activating solids in bins, hoppers, chutes, screens and feeders.

Best suited for fine, dry material
Ideal for parts handling, circuit board manufacturing and bottling plants
One third the air consumption of ball vibrators

Learn More

NTK^® Oscillators

This oscillator provides a great motive force for compaction tables, feeders, and screens.

Start and stop instantly in any position
Also available in a mini version for small hoppers and bins
Available with ATEX certification

Learn More

XHA™ Extra Hi-Amplitude Electric Vibrators

This electric vibrator offers high-amplitude, low-frequency vibration that resolves material flow problems in bins and hoppers.

Guaranteed for 3 years even when operated at 100% amplitude setting in a 24/7 environment
Ideal for dislodging lumpy, sticky, or light, fluffy materials

Learn More

XHD™ Extra Heavy Duty Electric Vibrators

This extra heavy duty vibrator is designed to withstand the rigors of even the toughest industrial environments.

Guaranteed for 3 years even when operated at 100% amplitude setting in a 24/7 environment
Eliminates clanging of noisy, air driven piston vibrators

Learn More

Compaction Vibrating Tables

Compaction tables are used to settle, compact and consolidate material. Normally the material is in a container being prepared for shipment.

Custom-made and designed specific to the application
Available with either electric or pneumatic drives.

Learn More

Why MARTIN®?

Our vibration solutions are built around the full scope of foundry bulk material handling — from raw material receiving through sand reclamation. Equipment needs to handle extreme heat, heavy abrasive loads, and continuous operation without failure, while delivering the controlled, consistent force that sand compaction, shakeout, and charge feeding require. For the most demanding foundry environments, our high-temperature rated vibrators are built to perform reliably where ambient temperatures exceed 450°F — where standard equipment simply can’t.

Contact our application experts to discuss how our equipment can improve throughput, casting quality, and worker safety at your facility. Engineering and application assistance is always free.