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 two different polymer concrete Autocaster systems - depending on your needs!

 
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 two machines - select which machine based on your matrix output needs - up to 100 lb (45kg) per minute matrix production with our standard machine, or up to 250 lb (113kg) per minute output with our 250 lb machine!

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

  • High-efficiency, easily replaceable tungsten carbide coated separate component mixing auger and case hardened mixing barrel

  • Three filler metering hoppers standard (more can be added)

  • Inverter-controlled motors for all raw materials

  • Accurate filler metering augers with integrated anti-bridging devices

  • Integrated resin heating system

  • Totalizer for all raw materials

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

  • Modular single Base Color system with removable base-color pump (more base colors can be added - see options)

Specifications:

MATRIX OUTPUT

100 lb machine - up to 100 pounds (44kg) per minute
300 lb machine - up to 300 pounds (136kg) per minute

MIXING SYSTEM

Case hardened barrel
High efficiency, variable speed mixer

MOTORS

230 Volt AC TEFC or optional explosion proof
Mixing unit – 7.5 HP
Raw material feed units - 3/4 HP
Thermal pump unit - 1/2 HP

FILLER SYSTEM

Three Filler (Metering) Hoppers standard
Inverter controlled adjustable output 4 - 100 pounds (10 - 44 kg)/min
Hopper capacity 4 cubic feet (0.113 cubic meters)
Integrated anti-bridging device for polymer concrete

RESIN SYSTEM

Maximum 2500 centipoise promoted polyester resin
Overpressure sensor and bypass
Inverter controlled adjustable output 1.5 to 15 lbs/min.
Integrated recirculating thermal fluid based heat exchanger with 12kW heater
Gravity feed resin input

CATALYST SYSTEM

Maximum 2500 centipoise promoted polyester resin
Overpressure sensor and bypass
Inverter controlled adjustable output 1.5 to 15 lbs/min.
Integrated recirculating thermal fluid based heat exchanger with 12kW heater
Gravity feed resin input

BASE-COLOR SYSTEM

One Base Color feed system standard (up to 3 additional can be added)
Precision gear pump
Uses liquid paste pigments up to 2500 centipoise
Inverter controlled adjustable output 0.1 to 1.0 lbs/min.
5 gallon storage tank

CLEANING SYSTEM

Dual cleaning system – internal and recirculating.
Air purge included
Internal cleaner 5 gallon storage, Recirculating cleaner 15 gallon storage
Recommended for use with DBE (Marblewash or equivalent)
Emergency flush valve

CONTROL SYSTEM

LCD Display and Keypad
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, 20 CFM

DIMENSIONS

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

NET WEIGHT

3500 lb (depending on configuration)

 

Order Information:

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

Autocaster Ultra/PC (Polymer Concrete) Continuous Casting System (250lb/113kg per minute) output - #1000PC250

 

Options:

  • Matrix batch meter with run-time reset for accurate mold filling

  • Additional metering hopper - #30ACFH

  • Add additional Base Color capability (beyond 1 base color provided in standard configuration) - to add 1 additional Base Color (#CMBCS-1C), to add 2-Colors (#CMBCS-2C), to add 3-Colors (#CMBCS-3C)

  • Fiberglass Strand Chopper - #700CA

  • Cobalt Unit - #151000

  • Expanded Heater Option - CALL

 

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.

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