Zinc Block Casting Machine

The zinc block casting machine is an example of how our research and development process has helped to set new world standards in product quality, high productivity at low production cost, and improved safety.

The project began when our market research identified a need in the zinc industry for a fully automatic block casting machine with a capacity of double the rate of existing technology. The challenge was to conceptualise a revolutionary method of casting to meet the industry objectives.

The proven Lewis process was applied to the challenge. The process started with a technology search which confirmed that the current technology was limited. Brainstorms were conducted to develop new innovative methods of casting. Once a concept was identified, extensive testing was completed to verify the technical feasibility of the concept.

The test work demonstrated a substantial increase in productivity at very low production cost through full automation, and the reduction of waste.

The design work followed and final detail drawings were completed within six months of the start of design. A full-scale verification machine was built to demonstrate to the industry that the concepts would provide the benefits that were promised by the concepts.

The construction, assembly and testing of the machine took approximately six months. The machine underwent hot test trials and was accepted at Lewis Australia.

As a result of this work, machines were sold and installed at the world's newest zinc smelter; Sun Metals smelter in Townsville, and at the Cominco Trail smelter within two years.

The second of these is the worlds fastest block caster and requires only one operator who monitors the machine. The machine gave the client the highest block casting rate in the world, the lowest operating cost and produces blocks that meet or exceed world's best quality levels.

It represents a significant competitive advantage to the client.