Turning up the heat Ferromatix

TURNING UP THE HEAT

After doubling its capacity recently, high-precision iron foundry Ferromatix is expanding its activities. Abigail Saltmarsh reports.

The past year has seen the results of great investment at high precision iron foundry Ferromatix in Belgium. Since doubling its capacity, the operation has decided to expand its activities and to focus firmly on the future.

Head of sales, Wim Vandendriessche, says the move has set the foundry on track for full recovery to getting back to where it was before the economic crisis by 2013. Then Ferromatix would be well-positioned for achieving growth rates of between 15 and 20 per cent year on year after that.

“This has very much been an investment for the future,” he says. “We have invested in the foundry and we have been investing in people. We are offering quality in design, development and production and we hope to have got back to where we were by 2013 – and then to continue to grow from there.”

A solid history

Ferromatix’s history goes back to 1953, when it was an integrated foundry activity within NV Michel Van de Wiele. In 1978, the foundry activity was divested and it became an independent company.

In 2000, a €14 million investment was made in an automated FMS-foundry. A total integration of shop floor control and quality control

saw the creation of one MES-system. Then in 2009, another €14 million investment was made, this time in a new automated moulding and melting department for large moulds.

Today the company manufactures a range of high-precision castings in grey, ductile and vernicular iron, as well as ADI cast iron and special alloyed cast iron (SiMo). Parts are made for gearboxes, wind turbines, turbochargers, compressors, pumps, diesel and gas engines and other machinery. Specialist areas

Since doubling its capacity recently, the high-tech foundry, which is part of the Van de Wiele group, has decided to expand its activities by also casting shipbuilding parts - in particular, critical parts such as cylinder heads and motor units.

And after the successful validation of its prototypes and at sector’s request, Ferromatrix was tested by several specialised classification societies. And this spring it was granted certifications by the classification societies Germanischer Lloyd and Det Norske Veritas.

“We are diversifying into some new, very specialised markets,” says Mr Vandendriessche. “These are small market applications for engines and some hydraulic parts.”

Increasing output

The most recent investment saw the creation of an ultramodern moulding line for castings of up to 5 tonnes (maximum weight of the filled flasks

38 tons), flasks with maximum dimensions of 4000mm by 3000mm – a furan sand mixer 100 tonnes per hour with several recipes.

Mr Vandendriessche explains that by 2007, output levels at Ferromatix had reached 13,000 tonnes. Then came the economic crisis and this figure was halved.

“But by 2012 we should be back up to 8000 tonnes and by 2013, we expect to have seen growth levels of 60 per cent – to get us back to where we were. The investment and the new focus should help us do that,” he says.

“We are just a small company and we have made these big €14 million investments. In between, we have made other, smaller investments in equipment.

“The investments will continue – in services and in research. We can continue here, as we are, until we reach 18,000 tonnes. Then by further enlarging the equipment, if we need to, we can produce up to 22,000 tonnes. However, because of the economic situation we think this is unlikely.”

Ready for growth

Ferromatix plans to maintain its customer base in Europe. It will continue to nurture its relationship with companies in northern and western Europe.

“In the beginning, until the investment in 2000, we served customers in Belgium, France and the Netherlands. After that, however, we opened up and began working with customers in places like Germany, Switzerland, Great Britain, Spain, Finland and Sweden.” He goes on: “There are values that we can bring to the products here in Europe. These include time-tomarket and offering advice from concept right through to design and production. We have the new material qualities and a wide range of grades.”

As part of the Van de Wiele group, the foundry also has strength and support. And he adds: “It is a big company but it is also fairly dynamic.

“We feel we have taken the right steps – and our team is ready for the future.” n