Process Control Equipment

Autocaster Continuous Casting Systems

Developed specifically for Polymer Concrete manufacturing applications.

Autocaster/PC Polymer Concrete Continuous Casting System

The Autocaster Ultra/PC (Polymer Concrete) edition system automates the production of polymer concrete matrix for cast polymer concrete manufacturing of a variety of durable cast products.

Replacing manual mixing with the Autocaster/PC (Polymer Concrete) Edition system can significantly increase productivity, cut material costs and improve quality - all leading to increased profits for the manufacturer. Our many years of experience with continuous casting machines and cast polymer manufacturing equipment have led to innovative improvements that have been incorporated into this purpose-built Autocaster specially designed for production of polymer concrete cast products.

Shown with optional fiberglass strand chopper.

 

Now choose from three different polymer concrete Autocaster machines - depending on your needs!

Assuming 7 hours/day of casting in an 8 hour shift, produce well over 200,000 lbs (95,000 kg) in a single shift! with the 500 lb/minute machine)

 
Provided with the base unit are three filler metering systems, one resin metering system, one catalyst metering system, and one base-color metering system. Additional raw material systems can be supplied as needed.

System Features:

  • Choose from three mixing system configurations depending on your output needs:
1)  30 – 100 lb (15 - 45 kg) per minute
2)  100 – 250 lb (45 - 115 kg) per minute
3)  250 – 500 lb (115 - 225 kg) per minute
  • PLC based recipe control system with on-the-fly matrix adjustments for resin %, catalyst % and matrix output

  • Expandable Base Color system (1 color standard) - option to add more (4 maximum)
  • High-efficiency, easily replaceable tungsten carbide coated separate component mixing auger and case hardened mixing barrel

  • Precise filler metering with three (3) included Filler Metering Hoppers (note: can be configured with more or fewer hoppers)

  • Accurate filler metering augers with integrated anti-bridging devices

  • Inverter-controlled motors for accurate delivery of raw materials
  • Resin system with integrated inline resin heating system

  • Totalizer for all raw materials

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

  • Compact footprint for tight production areas.

 

Specifications:

MATRIX OUTPUT

100 lb machine – 30 lb (15 kg) min., 100 lb (45 kg) max. output per minute
250 lb machine – 100 lb (45 kg) min., 250 lb (115 kg) max. output per minute
500 lb machine – 250 lb (115 kg) min., 500 lb (225 kg) max output per minute

MIXING SYSTEM

Case hardened barrel
High efficiency, variable speed mixer

MOTORS

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

FILLER SYSTEM

Three 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 device for polymer concrete

RESIN SYSTEM

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

CATALYST SYSTEM

Precision piston pump
Pressure sensor
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)
Precision gear pump
Liquid paste pigment up to 3000 centipoise (at working temperature)
Inverter controlled adjustable output
Storage capacity 5 gallons (18.9 liters) per base color

CLEANING SYSTEM

Dual cleaning system – internal and recirculating.
Air purge included
Internal cleaner 5 gallon (18.9 liter) storage
Recirculating cleaner 15 gallon (56.7 liter) storage
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
Integrated rate display and totalizers

ELECTRICAL SYSTEM

230/380/480 Volt, 3-Phase, 50/60 Hz, 80 amps max. Specify voltage.
24VDC control circuit

AIR SUPPLY

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

DIMENSIONS

54” wide x 80” deep x 112” high (137.2cm wide x 203.2cm deep x 284.48cm high)

NET WEIGHT

3500 lb (1600 kg) depending on configuration

 

Order Information:

Autocaster Ultra/PC (Polymer Concrete) Continuous Casting System - 30 - 100 lb (15 - 45 kg) per minute) output - #1000PC3H

Autocaster Ultra/PC (Polymer Concrete) Continuous Casting System - 100 - 250 lb (45 - 115 kg) per minute) output - #1000PC250

Autocaster Ultra/PC (Polymer Concrete) Continuous Casting System - 250 - 500 lb (115 - 225 kg) per minute output - CALL!

 

Options:

  • Additional Standard (Powder) Filler Metering Hopper – Three metering hoppers are standard, but add up to 3 more with this upgrade. Mix and match between powder and aggregate filler requirements. Can be configured with fewer than three as well - #30ACFH

  • Add additional Base Color - One Base Color is included in the standard configuration, but you can add additional base colors with this option. To add 1 additional Base Color (#CMBCS-1C), to add 2-Colors (#CMBCS-2C), to add 3-Colors (#CMBCS-3C)

  • Fiberglass Strand Chopper - Reinforce your cast part with this automatic Fiberglass strand chopper system. Automatically cuts 1-1/2” strands of fiberglass from a roll, and adds it to your matrix. Choose full or partial speed motor - #700CA

  • Expanded Resin Heating Option - In cold climates, or given particular matrix/resin percentages, we recommend the expanded inline resin heater option - #163500

  • Cobalt Promoter System – Use of a promoted resin is highly recommended. If using an unpromoted resin, then the Cobalt Promoter System Option is required - #151000

  • Remote Batch Display – matrix batch meter with run-time reset - #162966

  • Remote Operator Interface Terminal (OIT) – Replaces the standard arm-mounted control panel with a remotely located pedestal-mounted OIT. This also removes the arm and OIT from the machine - #1500ACB-R

 

View/Download Product Bulletin:

 

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 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.