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 output machine provides 33 – 77 lb (15 - 35 kg) per minute
Optional lower output machine (ie. specialized precision casting) - 15 - 33 lb (7 - 15 kg) per minute

MIXING SYSTEM

Case hardened barrel
High efficiency, variable speed mixer

VACUUM SYSTEM

Vacuum degasser auger.
Durable vacuum pump with both wet and dry filters.
Wet oil percolating filter removes styrene to extend pump life.
Dry filter removes dust and other contaminants.
Exit filter removes any remaining particles.
Lowest emissions of any continuous casting system.

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

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

MOTORS

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

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

3800 lb (1700 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 included standard (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) - #UCFMH
  • "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:

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.

© Copyright 2018 by Gruber Systems, Inc. All rights reserved. Specifications subject to change without notice. Autocaster and Batchmaster are trademarks of Gruber Systems, Inc.

Related 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

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

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

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 or 15 foot lengths

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

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


 

screenprotectorsmall

Display Panel Screen Protectors

For Autocaster Ultra and Economizer machines,
and Batchmaster II and III models!

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


Screen Protector Product Details