Process Control Equipment

Autocaster Continuous Casting Systems

Ultra CM325

The ultimate technology available for high throughput continuous casting!

 
Application: Automated, continuous casting for cast polymer and other composites manufacturing.

 

The Autocaster Ultra™ continuous casting machine and associated Ground Hoppers automate filler loading, recipe management, mixing and dispensing of cultured marble matrix for cast polymer manufacturing for unparalleled continuous casting production.
 
Replacing manual mixing and casting with the Autocaster Ultra™ will significantly increase productivity, cut material cost and improve quality – all leading to increased profits for the manufacturer.

Standard Features:

The Autocaster Ultra system is offered in a base configuration that includes the Autocaster™ Ultra Continuous Casting System, including 2 Filler Systems, 1 Resin System, 1 Catalyst System, 1 Base Color System, 2 Contrast Vein Colors, Recipe Control, Resin Heater, Dual Flush Cleaning System. Optional upgrades are available to customize your machine (options shown at bottom of this page). The base configuration includes these standard features:
  • Standard matrix output range from 30 - 80 lb/minute (13.6 - 36.2kg/minute), with options for as low as 25 lb (11.3 kg) or as high as 120 lb (54.4 kg) per minute available.
  • Recipe-based matrix control with on-the-fly adjustments for resin %, catalyst % and matrix output.

  • Recipes are stored using descriptive names, and include recipe backup.

  • Password protected touch-screen 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

  • Modular base-color system with removable base color pumps

  • Add up to two additional metering hoppers (2 standard) for a maximum total of four hoppers

  • Totalizer for all raw materials (except contrast color)

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

  • Accurate auger-based filler metering system with integrated anti-bridging devices

  • Adjustable flow contrast color injectors

  • High-efficiency mixing system with hardened steel machined mixing auger

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

  • Easy and convenient post-production cleanup with two-stage cleaning system and final air purge.

  • Alarm logging

 

Standard Specifications

Matrix Output
  • Standard matrix output range from 30 - 80 lb/minute (13.6 - 36.2kg/minute), with options for as low as 25 lb (11.3 kg) or as high as 100 lb (45.4kg) per minute available.
Mixing System
  • Hardened steel auger
  • Sectioned auger available
  • High efficiency mixer
Filler System
  • Inverter controlled adjustable output
  • Maximum particle size 2mm
  • Hopper capacity 4 cu. ft. (0.113 cubic meters)
  • Integrated anti-bridging device
  • Optional High Output Metering Hopper
Resin System
  • Maximum 2000 centipoise 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
  • Filter strainer on resin inlet
Catalyst System
  • Unique precision piston pump
  • Overpressure sensor and bypass
  • Recirculating system with electronic flow sensor (in Run mode) and visual display
  • Inverter controlled adjustable output
  • Storage capacity of 5 gallons (18.9 liters)
Base Color System
  • Positive displacement gear pump
  • Uses liquid paste pigments up to 2500 centipoise (at operating temp.)
  • Inverter controlled adjustable output
  • Pigment recirculation to reduce solids separation
Contrast Color System
  • Use liquid paste pigments up to 2500 centipoise (at operating temp.)
  • 0.0 to 999.9 second pause and pulse settings
  • Injectors incorporate flow control knob
  • Recipe-controlled on/off cycling
Cleaning System
  • Two-stage cleaning (fresh and recycled cleaning solutions), with air purge.
  • 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
  • Recipe presets with on-the-fly adjustments for resin, catalyst and output
  • Control panel mounted on adjustable arm, or optional remote pedestal
  • Integrated rate display and totalizers
Motors
  • 230 VAC TEFC (optional explosion-proof upon request)
  • Mixing unit
  • Raw material feed
  • Thermal pump
Electrical System
  • Choose from standard 230V/3-Phase/60Hz or 480V/3-Phase/50-60 Hz. Others supported.
  • 24VDC control circuit
Dimensions
  • 52” wide x 114” deep x 114” high (132cm x 289cm x 289cm)
Air Supply
  • 90 psi (620 kpa), 20 CFM (0.01 cubic metre/second)
Net Weight
  • 3500 lb (1600kg) depending on machine configuration

 

Order Information

Base System - Description/Order Number

  • Autocaster Ultra Continuous Casting System for Cultured Marble, 230V/60Hz (w/ Base Configuration) - #1000AW2H*

  • Autocaster Ultra Continuous Casting System for Cultured Marble, 380-480V/50-60Hz (w/ Base Configuration) - #1000AW2H-480*

*Other voltages available. Specify voltage when ordering
 
Base configuration shown above includes:
  • 2 filler metering hoppers (maximum 4 total)
  • 1 resin system with heater
  • 1 catalyst system
  • 1 base color (maximum 8 total)
  • 2 contrast veining colors (maximum 8 total)
  • Recipe control with named recipes and recipe backup
  • Dual (fresh/recycled material) cleaning system
  • Choice of 230V/60Hz or 380-480V/50-60HZ electrical power standard

Optional Upgrades - Description/Order Number

  • High output options of 50-120 lb (22.6-54.4kg) per minute available
  • Low output options of 25-50 lb (11.3-22.6kg) per minute available
  • Add a Metering Hopper (each) - #30ACFH
  • "High Output" Metering Hopper available - #30ACFHHC
  • Add 1 Base Color - #CMBCS-1C
  • Add 2 Base Color - #CMBCS-2C
  • Add 3 Base Color - #CMBCS-3C
  • Add Vein Color (each) - #162535
  • Cobalt Injector Assembly Option - #151000
  • Digital Batch Display Assembly - #162966
  • Expanded Heat Exchanger (High Output Option) - #163500
  • Mezzanine Option (raised platform) for easy access to Metering Hoppers
  • Pneumatic Gate Option
  • Cartridge Filter Upgrade
  • Machine Commissioning - #009903

View/Download:

 

Related Accessory Products:

A number of related filller handling and conveying products are used with Autocasters to increase your productivity and efficiency. Discuss these and other options with your Gruber representative before ordering:

Standard Powder/Granule 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 Gantries - 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)

XYZ Mechanized Casting Table (MCT) - 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.

 

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 buyer’s expense.

LCD Screen Protectors for Autocaster Ultra

screenprotectorsmallAvailable for Autocaster Ultra and Autocaster Economizer 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 (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