Process Control Equipment

Autocaster Continuous Casting Systems

Ultra CM325

The ultimate technology available for high throughput continuous casting!

 
Application: Automated, continuous casting for cultured marble and cultured onyx 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

 

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

Case hardened barrel
High-efficiency mixer
Sectioned auger and High Output augers available

FILLER SYSTEM

Two (2) Filler Metering Hoppers standard, Maximum of 4 permanent/fixed hoppers available.
Inverter controlled adjustable output
Hopper capacity 4 cubic feet (0.113 cubic meters)
Integrated anti-bridging
Optional High Output Metering 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
Filter strainer on resin inlet

CONTRAST (VEINING)

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

CATALYST SYSTEM

Precision piston pump
Pressure sensor with overpressure 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

CLEANING SYSTEM

Dual-stage cleaning system (fresh and recycled)
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

Large 15" touch screen
Recipe presets with on-the-fly adjustments for resin, catalyst and output
Control panel mounted on adjustable arm, or choose optional remote pedestal
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 230V/3-Phase/60Hz or 480V/3-Phase/50-60 Hz. Others supported.
24VDC control circuit

AIR SUPPLY

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

DIMENSIONS

52” wide x 114” deep x 114” high (132cm x 289cm x 289cm)

NET WEIGHT

3500 lb (1600 kg) depending on 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 additional Metering Hopper (each) - #30ACFH
  • "High Output" Metering Hopper option - #30ACFHHC
  • Add additional Base Colors:
    • 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 - CALL
  • 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.

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