This document provides information about Donsco Inc., a company that specializes in matchplate molding. It produces castings weighing between 5 and 80 lbs for the agricultural, truck, and automotive industries using three green sand molding lines. The document outlines opportunities like increased production and improved quality, as well as challenges faced and details of the matchplate molding process used.

1. This fact sheet was prepared as an account of work sponsored by the Pennsylvania Department of Environmental Protection (PaDEP.) Neither the PaDEP, these participants nor the organizations listed herein, nor any person on behalf of any of the organizations mentioned herein: makes any warranty, expressed or implied, with respect to the use of any information, apparatus, method, or process disclosed in this document or that such use may not infringe privately owned rights; or assumes any liability with respect to the use of, or damages resulting from the use of, any information, apparatus, method or process disclosed in this document. Donsco Inc., Belleville Div. One of the Best in Matchplate Molding Donsco was founded in 1972 as a captive facility to New Holland. In 1993 it became a job shop requiring renovations in operating philosophy and equipment. Its current 125 employees pour gray and ductile iron. There was nearly a complete turnover in workforce during the transition period. Donsco now runs 3 green sand molding lines with cold box and shell cores. The castings, weighing between 5 and 80 lbs, are sold to the agricultural, truck and automotive industries. Opportunities Average 100 molds per hour Increased surface finish 1300 psi squeeze pressure Improved dimensional stability Improved grinding efficiencies in cleaning room Challenges Systems designed to eliminate human variables Installation led to 3.3% internal scrap rates Current scrap rates dropped to 2.2% Process Details Three 20x24 matchplate green sand molding lines HMP-20 (Hunter Automated Machinery Corp.) HLH-20 linear mold handling system featuring double-row pouring/cooling lines (Hunter) Self storing mold conveyor Automatic Weight and jacket setter Cooling Conveyor Electronic monorail for efficient iron transport Good green sand for molding Contact Chuck Cutshall, Plant Manager Donsco Inc., Belleville Div. Phone Number: (717) 252 1561 Email: ccutshall@donsco.com Reference: “The Best of Matchplate Molding”, Modern Casting , August 2003, pp. 28-29 “ Attention to detail is what makes us successful” - Chuck Cutshall