Process Control Equipment

Autocaster Continuous Casting Systems
Polymer Concrete Economizer

Application:  Automated, continuous casting of cultured marble or polymer concrete matrix for low to medium production requirements.

Autocaster Economizer now available in either Cultured Marble or Polymer Concrete editions!

Like the Autocaster Ultra, the Autocaster Economizer automates the production of polymer matrix for cast polymer manufacturing, replacing manual mixing methods with the automated, continuous casting capability. Like the Autocaster Ultra, the Economizer will significantly increase productivity, cut material cost and improve quality all leading to increased profitability for the manufacturer.

The Economizer is intended for medium volume production requirements. It does not include all the features and capacity of the higher capacity Autocaster Ultra, but provides many of the benefits of continuous casting at a lower price point.

The Economizer is available in a base configuration, but has fewer customization and expandability options than the Ultra. If you find that you need features available exclusively with the Ultra, or your production requirements are increasing over time, you may find that the Ultra provides a better long term casting solution for your requirements.

The base system described here is the Ecnomizer for Cultured Marble manufacturing, but this machine can be provided as a basic Polymer Concrete casting system with some replacement of certain equipment. Call for assistance in configuring a polymer concrete machine. Also see the Autocaster Ultra/PC Polymer Concrete casting system.

Features:

  • Standard Cultured Marble Auger equipped mixing system providing 15 – 30 kg output per minute (base configuration version), or higher output ranges (up to 40 kg per minute) with optional augers.

  • Recipe-based matrix control with on-the-fly adjustments for resin %, catalyst % and matrix output

  • Recipes are stored as a Recipe number (rather than a recipe name on the Ultra)

  • Password protected control panel with color display gives access to all functions including metering calibration, recipe definition, totals, diagnostics, alarms, setup and cleaning

  • Integrated resin heating system

  • High-efficiency mixer with hardened steel mixing auger

  • Modular base-color systems with removable base color pumps

  • Totalizer for all raw materials (except contrast color)

  • Precision metering pumps for resin and base-color, and piston pump for catalyst

  • Accurate filler metering auger with integrated anti-bridging devices

  • Adjustable flow contrast color injectors

  • Inverter controlled motors for all raw materials (except contrast color)

Specifications

MATRIX OUTPUT*

30 - 60 lb (15 - 30 kg) per minute with Standard Cultured Marble Mixing Configuration
40 - 80 lb (20 – 35 kg) per minute with optional High Output Cultured Marble Auger
50 - 90 lb (20 – 40 kg) per minute with optional Sectioned Auger
*Applies to Cultured Marble and/or Polymer Concrete Machines

MIXING SYSTEM

Optional auger types available for higher matrix production ranges
Case hardened barrel
High-efficiency mixer

FILLER SYSTEM

One (1) Filler Metering Hopper standard (can additional hoppers for maximum of 4 permanent/fixed hoppers).
Inverter controlled adjustable output
Hopper capacity 4 cubic feet (0.113 cubic meters)
Integrated anti-bridging
Optional High Output Metering Hopper
Maximum particle size 2mm (approx. 0.078") (in standard powder hopper)

RESIN SYSTEM

Promoted resins (or cobalt promoter system option required)
Maximum 2500 centipoise (at working temperature) promoted polyester resin
Overpressure sensor and bypass
Inverter controlled adjustable output
Integrated recirculating thermal fluid based heat exchanger with 12kW heater
Gravity feed resin input with inline mesh filter strainer

CATALYST SYSTEM

Precision piston pump
Pressure sensor with over pressure bypass
Recirculating system with dual electronic flow sensors and visual display
Inverter controlled adjustable output
Storage capacity 5 gallons (18.9 liters)

BASE-COLOR SYSTEM

One Base Color feed system standard (up to 7 additional can be added)
Positive displacement precision gear pump
Liquid paste pigment up to 3000 centipoise (at working temperature)
Inverter controlled adjustable output
Pigment recirculation to reduce solids separation
Storage capacity 5 gallons (18.9 liters) per base color

CONTRAST (VEINING) SYSTEM

Use liquid paste pigments up to 2500 centipoise (at operating temperature)
0.0 to 999.9 second pause and pulse settings
Injectors incorporate flow control knob
Recipe-controlled on/off cycling

CLEANING SYSTEM

Dual-stage, hands-free automated closed loop cleaning system (using both fresh and recycled fluids)
Air purge included
Fresh cleaning solution storage capacity - 5 gallons (18.9 liters)
Recycled cleaning solution storage capacity - 15 gallons (56.8 liters)
Recommended for use with DBE (Marblewash or equivalent)

CONTROL SYSTEM

Integrated touch screen controlled Control Panel
Save, store and load recipes
Recipe presets with "on-the-fly" (instantaneous) adjustments for resin, catalyst and output
Integrated rate display and totalizers

MOTORS

TEFC or optional explosion proof
Mixing unit
Raw material feed units
Thermal pump unit

ELECTRICAL SYSTEM

Choose from standard 230/380/480 Volt, 3-Phase, 50 or 60Hz (other supported)
24VDC control circuit

AIR SUPPLY

90 psi (620 kPa), 20 cfm (566 lpm)

DIMENSIONS

41” wide x 89” deep x 98” high (104 cm wide x 226 cm deep x 249 cm high)

NET WEIGHT

3000 lb (1360 kg) depending on configuration


Equipment Requirements: All models should be hard-wired to an appropriate circuit by a qualified electrician to meet your local electrical codes. Additional controls may be necessary to meet your local regulations. Any additional requirements needed to deem this equipment operational will be obtained by buyer at buyers expense.

Order Information

Description/Order Number
Autocaster Economizer (base configuration) - #30AW1H

Choose from these variations:
  • Autocaster Economizer, (base configuration with 230V) for Cultured Marble, Crated - 30AW1H-230*
  • Autocaster Economizer, (base configuration with 380V) for Cultured Marble, Crated - #30AW1H-380*
  • Autocaster Economizer (base configuration with 380V) for Cultured Marble, No Base Colors or Contrast Colors, Crated - #30AW1H-380NC*
  • Autocaster Economizer, 230V, Small, for Polymer Concrete, Crated - #30AW1HPC-230**

* Base cultured marble machine configuation includes:

  • Standard Mixing Auger
  • One (1) Metering hopper (3 maximum option)
  • One (1) Base color (4 maximum option)
  • Two (2) veining colors (4 maximum option)
  • Resin heater
  • Catalyst system
  • Two-stage cleaning (fresh and recycled cleaning solutions), with air purge.

** Base polymer concrete machine configuation includes:

  • Polymer Concrete Mixing Auger
  • One (1) Metering hopper (add up to 2 additional hoppers by adding Small Aggregate, Large Aggregate, or High-Volume Metering Hopper upgrades shown below)
  • One (1) Base color (4 maximum option)
  • Resin heater
  • Catalyst system
  • Two-stage cleaning (fresh and recycled cleaning solutions), with air purge.
Optional Economizer Upgrades
add Metering Hopper Assembly (each) - #30ACFH
add "High Output" Metering Hopper - with open auger flights
add Small Aggregate Fller Metering Hopper (for Polymer Concrete Economizer only) - with solid core auger shaft
add Large Aggregate Fller Metering Hopper (for Polymer Concrete Economizer only) - with solid core auger shaft
add 1 Base Color - #CMBCS-1C
add 2 Base Color - #CMBCS-2C
add 3 Base Color - #CMBCS-3C
add Vein Color (each) - #162535
Digital Batch Display Assembly - #162966
Polymer Concrete Mixing Auger upgrade - CALL
Cartridge Filter Upgrade - CALL
Expanded Heat Exchanger (High Output Option) - CALL
Machine Commissioning - #009903 (USA) or 009904 (International)

Crating
Crate - Casting Machine - #CECSTMACH
Crate - Metering Hopper - #CEHOPPER

Literature:

Equipment Requirements: All models should be hard-wired to an appropriate circuit by a qualified electrician to meet your local electrical codes. Additional controls may be necessary to meet your local regulations. Any additional requirements needed to deem this equipment operational will be obtained by buyer at buyers expense.

Optional Autocaster Accessories

A number of related filller handling and conveying products are used with Autocaster systems (Ultra for Cultured Marble or Solid Surface and Economizer for Cultured Marble) to increase your productivity and efficiency. Discuss these and other options with your Gruber representative before ordering:

Standard (Powder) Ground Hopper - Stores and conveys bulk powder materials to the point of insertion or use. Utilizes a solid core auger. Often used in conjunction with a gantry or other material transfer system to store and deliver super sacks or bulk bags to the ground hopper - #1000AGH

Pneumatic Ground Hopper - Automatically transfer bulk lightweight filler material with a Ground Hopper equipped with a pneumatic pump and hose transport system - to pneumatically transport powder and lightweight fillers, remote positioning of the Ground Hopper relative to the Autocaster. - #1000AGHAO

Bulk Bag Suspender Frame - Suspend a bulk bag or Super Sack above a Ground Hopper for higher efficiency bulk powder filling and management - #150160

Bulk Bag Gantry - The 4-leg bulk bag gantry is used to transport a bulk bag from a pallet and suspend it over the ground hopper using a hoisted trolley. Available in 10 foot (#0831208) or 15 foot lengths (#162768)

Automated Casting Tables - an XYZ motion casting table designed to allow mold adjustments under the Autocaster - including vertical movement - #150110

Mold Handling Conveyors - Consult with your Gruber representative for a configuration to suit your needs.


 

Display Panel Screen Protectors

screenprotectorsmall

Keep your machine's Control Panel screen clean and readable!

Available for Autocaster Ultra, Autocaster Economizer and Batchmaster II and III models!

  • Extend the life of your touchscreen and keep it looking like new!
  • Long lasting protection against dust, scratches and gouges.
  • Abrasion and chemical resistant to protect the LCD screen. Now clean matrix off the screen protector with acetone!
  • Anti-glare film provides added screen contrast and brilliant colors.
  • Installs easily, removes cleanly without leaving residue.
  • Filters out 99% of UV light from reaching your screen or reflecting to your eyes.
  • Reduce expensive service calls or touch screen replacements due to screen damage

Order Information

  • For Autocaster Ultra/PC systems from 2015 and newer Autocaster Ultra (fits TP1500 screen) - Order No. 166117  - USD $24.00
  • For Autocaster Ultra/PC systems pre-2015 (2014 and earlier) (fits MP370/377 screen) - Order No. 166120 - USD $15.50
  • For Batchmaster III and pre-2012 Autocaster Economizer systems (fits HG2F screens) - Order No. 166119 - USD $12.46
  • For 2013+ Autocaster Economizer systems (fits HG3F screens) - Order No. 166118 - USD $15.54
  • For Batchmaster II systems (fits TP170A screen) - Order No. 180376 - USD $12.46