IUSA MFG OVERVIEW

MANUFACTURING
PROCESSES
OVERVIEW
1

INDEX
GLASS
MELTING
4
8
12
16
20
24
6
10
14
18
22
NODULAR
IRON CASTING
NON-FERROUS
MELTING DIE CASTING
CONTINUOUS
CASTING
CERAMIC
MOLD CASTING
PLASTIC
INJECTION
MOLDING
PERMANENT
MOLDING
ROTATIONAL
MOLDING
ASSEMBLY
OF PRODUCTS
GALVANIZING
2

4
GENERALCATALOGMANUFACTURINGPROCESSES
Formulas are prepared according to the master
list of components added for each type of
piece. Each element is weighed in a scale with
a dust collector, and is then transferred to a
hopper. Secondary components are added to
the main elements in the hopper to complete
the formula.
1 PREPARATION OF
MIXTURES
PROCESS
2
INTRODUCING RAW
MATERIALS INTO
THE FURNACE
The formula in the hopper and dust collector
is continuously fed into the surface of the
furnace through a distribution arm in order to
full fuse the glass into a uniform layer.
3 GLASS MELTING
Glass undergoes a 5-step melting process in a
fully-electric furnace as follows:
•Melting tank
•Fining tank
•Throat
•Elevator
•Sandblasting unit (the glass temperature is controlled
by the combustion of gas and air in order to give the
glass the proper volume, shape and weight depending
on the piece to be manufactured).
Soluble oil is used to cool and lubricate the
drop-cutting blades. A closed-circuit water
cooling system is integrated into the furnace.
4 GLASS PRESSING
Glass drops are formed into gobs with the
specifications of the piece to be shaped. Then,
a 12-position hydraulic press, steel molds and
a core piston are used to shape the glass.
Molds are continuously lubricated with oil
through rubber rolls.
5 HOMOGENIZATION
TANK
At this stage, glass is transferred from the press
to the furnace to apply heat homogeneously
at a temperature of 615 °C. Natural gas is
used in order to temper glass better.
8 SELECTION OF FINISHED
PRODUCT
Every piece in the manufactured batch
undergoes quantitative and qualitative
inspection to eliminate the gobs that do not
meet the physical requirements outlined in
our procedures and operation guidelines.
Pieces may be discarded if they are:
•Incomplete
•Cracked
•Scratched (with bright superficial lines)
6 GLASS TEMPERING
The glass gob comes out of the press at an
approximate temperature of 800°C. The gob
goes through a train of natural gas burners
and air for the piece to have a homogeneous
temperature of 750 °C. Then, the gob
goes into a carousel where air is injected
at a different volume and temperature to
abruptly decrease the material temperature to
approximately 200 °C.
7 TEST LINE
The tempered glass gob is carried through
natural gas modules by a metal conveyor as
to test the resistance of the glass to thermal
shock. Thermal resistance tests are divided as
follows:
•POSITIVE: the glass piece is moved from an area at
room temperature to an enclosure at 380°C
•NEGATIVE: the glass piece is heated up to
approximately 140°C and then placed inside a water
container at 20 °C. This container has a closed-circuit
cooling system.
9 PACKAGING
During packaging, the full batch undergoes
inspection, and is then placed inside its
package to be sent to the point of assembly
or shipped as a finished piece.
FEATURES AND ADVANTAGES
• Automatic weighing system
• National raw materials
• 100% electric melting system with impurity-
removing system
• 12-position hydraulic press
• Improved tempering process
• 18-position annealing lehr with forced air
injection
• Natural gas combustion system and automatic
temperature control
• Full batch verification
• Release warranty for products held in
quarantine
• Qualitative and quantitative verification of the
finished product
CERTIFICATES
•Certified supplier by the testing, equipment
and materials laboratory of the federal electricity
commission (LAPEM CFE)
•ISO 9001-2008
QUALITY CONTROL
•Glass gob quality control
•Chemical control of raw materials
•Melting temperature control in furnace
•Gob temperature control
•Gob weight control
•Temperature control of the homogenization
furnace
•Tempering cooling control
•Temperature control of routine tests
•Temperature control of thermal-shock-inducing
water
•Finished product quality control
•Quality control of mechanical resistance tests

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NODULAR
IRON CASTING

6
Cores are manufactured using cold box or
hot box techniques, as well as a compound
mixture of silica and resins. Pneumatic pressure
is applied while casting into the desired shape.
Then, a catalyst is added to the mold to
harden the iron compound. Finally, the mold
is removed after the metal has cooled down.
1 FABRICATION OF CORES
PROCESS
2 METAL MELTING
Metal scraps, graphite flakes and ferro-silicon
are cast in order to obtain the gray iron alloy
requested by the client. Materials are melted
by applying heat to a core-free induction
melting furnace operating at the frequency of
the network.
3 FABRICATION OF MOLDS
At this stage of the process, high-density
sand molds are manufactured by pressurized
blow molding machines that compress and
shape the materials according to the selected
pattern plates. The plates are placed opposite
from one another to create a two-face mold
with vertical injection.
4 METAL TREATMENT
PROCESS
Graphite flakes from the cast iron base
are turned into nodes (pellets) through
the incorporation of a ferrous alloy with
magnesium.
5 METAL STRAINING
PROCESS
The previously manufactured molds are filled
with cast iron, which is then treated according
to the desired specifications.
6 FINISHING
The cast iron pieces are thoroughly cleaned
from superficial impurities and rough seams.
7 SHIPPING
The cast pieces are shipped according to the
delivery schedule and conditions previously
agreed on with the client in order for
the supplied materials to be available for
subsequent manufacturing processes.
FEATURES AND
ADVANTAGES
•Compliance in size.
•Compliance with production standards.
•Dual-track melting process.
•Automatic molding and coring process .
•High-efficiency molding process.
•Semi-automatic casting process with timer-
controlled straining.
•Permanent supervision during manufacturing
process.
•High-quality warranty.
CERTIFICATES
•ISO 9001 2008
QUALITY CONTROL
Fabrication of cores:
•Regulated amount of resins and catalyst.
•Controlled curing time and temperature.
Metal melting:
•Calculation of loads.
•Classification of scraps.
•Initial and final chemical control.
•Melting temperature control through an
immersion pyrometer that regulates the metal
volume injected into the line.
Fabrication of molds:
•The mold manufacturing equipment operates
with the following components and parameters
according to the pieces to be cast:
•Plates.
•Width.
•Core.
•Pressure.
•Speed.
•Compressibility.
Metal treatment process:
•Magnesium ferrosilicon.
•Inoculant amount control.
•Metallographic analysis to test materials for
compliance with the client’s requirements.
Metal straining process:
•Cast temperature.
•Cast time.
•Number of strained molds.
•Final chemical analysis per piece.
•Final metallographic structure.
Finishing:
•Visual inspection of surface cleanliness.
•Separation of defective pieces.

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NON-FERROUS
MELTING

8
Metals (copper, aluminum, tin, etc.) are
molten at high temperatures (depending
on the melting point) in tilting-type melting
furnaces driven by a mix of natural gas and air
to obtain the required alloy
1 METAL MELTING
PROCESS
2 FABRICATION OF MOLDS
Molds are manufactured through the CO2
process with a mix of sodium silicate and silica
sand. The materials are put in a molding box
with the required model plate, and are then
pressed in two stages:
•Upper
•Lower
The molding boxes are removed from the
model plate, and pressed together to prevent
metal leaks. Once the two halves of the mold
are joined, the mold is ready to get the molten
metal into the desired shape
3 CASTING
Molten metal is poured into the previously
manufactured molds to obtain the desired
piece.
4 SHIPPING
Pieces undergo the final steps before being
dispatched. Finishing requires 3 steps:
•Cutting: the piece is separated from the casting
system
•Grinding: burrs and rough seams are removed from
the piece
•Blasting: the surface of the piece is cleaned
5 SHIPPING
subsequent manufacturing processes
FEATURES AND
ADVANTAGES
•Multiple copper-based and aluminum-based
alloys available.
•Internal manufacturing of molds.
•Easy-to-use machinery.
•Full compliance with the client’s
specifications.
•Full-batch quality control.
CERTIFICATES
•ISO 9001:2008
QUALITY CONTROL
•Calculation of loads depending on type of
alloy.
•Final chemical analysis of the alloy.
•Pressing pressure.
• Resistance to sand.
•Casting temperature.
•Control of cast molds.
•Cast speed.
•Metal inlet size measurement.
•Measurement of separation between piece
and feedline.
•Visual inspection of grinding conditions.
•Visual inspection of state of cleanliness.
•Separation of pieces with superficial flaws.
•Quality certificate in every batch.

10
Aluminum (A380) or Zamac (aluminum, zinc,
magnesium and copper alloy) is forced or
injected into a permanent mold and placed in
a 3-phase cold chamber.
1
PROCESS
2 METAL MELTING
Metal is melted to obtain the alloys requested
by the client. Metals are melted in a tilting-
type furnace and a combustion furnace at 680
°C until the desired alloy is obtained.
3 VERIFICATION OF ALLOY
COMPOSITION
The alloy undergoes chemical verification
tests. Gas is removed from the materials, and
then the vacuum tests are performed.
4 METAL INJECTION
Once aluminum is melted and heated up to
the temperature required by the alloy and the
final product, materials are cast into the mold
and pressure is applied to obtain the final
piece.
5
6
FINISHING
SHIPPING
Pieces are checked for compliance with the
required specifications.
FEATURES AND
ADVANTAGES
•Being a continuous production process, die
casting is a low-cost alternative.
•Pieces may be manufactured in different sizes
and complex shapes.
•Outstanding precision in manufacturing size:
+-0.001”
•Feasible production of pieces up to 8 kgs.
•Secondary operations are unnecessary due
to the flawless finishing of the pieces, hence
eliminating deburring and blasting.
•The final pieces have smooth finishings free
of pores.
•Permanent supervision during the production
process.
CERTIFICATES
ISO 9001:2008
QUALITY CONTROL
•Melting temperature control.
•Spectrometry for chemical analysis.
•Gas removal to prevent pores and cracks.
•Vacuum test tubes to verify absence of pores
and cracks.
•Size control and verification.

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CONTINUOUS
CASTING

12
Rawmaterialsarecheckedtoverifycompatibility
with the most commonly produced alloys and/
or the client’s specifications in terms of their
chemical composition.
1 RECEPTION
OF RAW MATERIALS
PROCESS
2 METAL MELTING
Approved raw materials are melted in electric
induction furnaces operating at the rate of the
production network. A sample of the molten
metal is taken with specially engineered test
tubes (polishing one of the faces), and is then
sent to the chemical quality lab to be analyzed
with optical emission spectroscopy. This
analysis detects and registers the % of metal
components present in the sample.
3 ALLOY ANALYSIS
The representative sample must be compatible
with the expected alloy. Otherwise, the
amount of metal components in the furnace
is modified, meaning that metals or chemical
compounds will be added to meet the
required percentages as per ASTM standards.
These standards set a reference framework for
the quality and composition of the products
supplied to our clients.
4 FABRICATION OF INGOTS
Following the approval of the quality
department, the molten metal is cast into
another induction furnace at a temperature
that keeps metal in liquid state according to
the requirements necessary for its subsequent
casting into ingots. Then, the metal is cast into
a mold in a controlled way, either through the
furnace or a proportioner.
Metal is shaped into ingots through a high-
efficiency heat exchanger called mold
(temperature is reduced from a range between
1160 °C and 1100 °C to 25 °C).
5 INGOT CUTTING
Ingots are cut with a power saw into the shape
necessary according to the requirements of
the subsequent extrusion and pressing stages.
6 SHIPPING
FEATURES AND
ADVANTAGES
•Backflow is avoided since the void generated
due to contraction is immediately filled.
•Cross-segregation is reduced, while
longitudinal segregation disappears due to the
relatively small size of the sections of the ingot.
•Continuous casting is easier and quicker since
ingots are not placed in preheating furnaces
and are not subject to trimming, hence
decreasing the operational costs.
•Permanent supervision of the production
process.
CERTIFICATES
ISO 9001 2008.
QUALITY CONTROL
•Chemical analysis of raw materials, in-process
product, and finished product with optical
emission spectroscopy and oxygen calculation
equipment (tests vary according to type of
alloy.)
•Control, registration and identification
of batches of raw materials, molten metal,
finished product, non-compliant product, and
rejected product.
•Final inspection of individual finished pieces.
•Step-by-step process performance
measurement.

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CERAMIC
MOLD CASTING

14
The powdered paste is mixed according to
the required specifications in terms of grain
size and raw materials. Once the elements
have been mixed, the paste is put in metallic
containers to keep proper moisture levels. The
same containers will be used in subsequent
stages of the process.
1 PREPARATION
OF THE PASTE
2
The grained paste is pressed in a metallic
container. Pressure is applied to shape the
piece according to specifications. Once the
piece has been shaped and released from
pressure, it is placed on a wooden base and a
rack to let it stand.
3 DRYING
The pieces (with 11% moisture content) are
place in drying chambers at a temperature of
80 °C to decrease moisture levels to 3%.
4 POLISHING / DEBURRING
The piece is checked for rough edges and
excess materials which are then removed.
5 ENAMELING
The piece is placed on a rotary grid at 360
°C and enamel is uniformly applied through
aspersion according to specifications.
6 BAKING
The pieces are automatically placed in a roller
hearth furnace. Once inside, the pieces
undergo 3 baking stages ranging between
75 °C and 1085 °C.
•Pre-heating
•Sintering
•Cooling
7 INSPECTION
Once out of the furnace, the piece is
checked for compliance with the established
parameters.
8 SHIPPING
FEATURES
AND ADVANTAGES
•Compliance with size requirements
•Compliance with production standards
•High-efficiency molding time
•Automatic sintering
•Permanent supervision of production
process
•High-quality warranty
CERTIFICATES
•Clean industry
•ISO 9001-2008
QUALITY CONTROL
•Verified compliance with specifications
•Full check to identify cracks
•Moisture content control
•Full visual check of the finished piece
•Enamel density control
PROCESS

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PLASTIC
INJECTION MOLDING

16
Virgin resin is loaded into a heater where
the material is dried at specific temperatures
depending on the type of polymer to eliminate
moisture accumulating on the surface due to
storage and transportation conditions.
1 DRYING MATERIALS
PROCESS
2 MOLDING OF THE PIECES
•Materials are loaded into the injection machine.
•Materials are molten inside the machine.
•Materials are injected into the mold.
•Materials cool down and take the shape of the
mold.
•The piece is unmolded
3 INSPECTION
The pieces undergo inspection to ensure full
compliance with the specifications agreed on
with the client.
4 SHIPPING
FEATURES AND
ADVANTAGES
•Quick cycles: 30 - 60 seconds per cycle
•Finished product after unmolding
•Ensured material uniformity throughout the
batch
•Continuous process with feasible 24/7
operation
•Ideal for big scale production
•Highly-versatile process in terms of available
shapes and materials:
•Noryl™ with fiberglass (PPO)
•Acrylonitrile butadiene styrene (ABS)
•Polycarbonate (PC)
•High-density polyethylene (HDPE)
•Polypropylene (PP)
•Low-density polyethylene (LDPE)
•Polyoxymethylene (POM)
•Polyvinyl chloride (PVC)
CERTIFICATES
ISO 9000:2008
ANCE
QUALITY CONTROL
•Standard operation procedures
•Hourly production registry
•On-site inspection at the machine
•Fabrication and maintenance of molds:
•Computer numeric control (CNC)
•Penetration machines (electrical discharge
machining)
•Jig grinder
•Stereolithography equipment for resin
prototypes
•Thermal treatment equipment

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PERMANENT
MOLDING

18
Copper, aluminum and recirculated metal
scraps are molten in a core-free induction
furnace in order to obtain a bronze-aluminum
alloy
1 FUSION
PROCESS
2 MOLDING
The copper-beryllium molds are automatically
filled to cast the desired pieces
3 FINISHING
Pieces are given their final appearance by
cutting, sanding and deburring metal seams
4 SHIPPING
FEATURES AND
ADVANTAGES
•Fusion is controlled in each furnace through a
potentiometer.
•Permanent molding allows more precise
casting of all the pieces.
•Automatic process.
•Time-efficient process.
•Improved cost-reduction.
process.
•Quality warranty of the cast product.
CERTIFICATES
•N/A
QUALITY CONTROL
•Chemical analysis.
•Temperature control during injection into
molds.
•Dimensional analysis of molds and pieces.
•PLC-controlled movement.
•Dimensional analysis of each piece.
•Visual inspection and separation of defective
cast pieces.
•Batch arrangement and verification.

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ROTATIONAL
MOLDING

20
A powdered polymer is poured inside the
mold. Then, the mold is hermetically sealed.
The amount of polymer must be calculated
according to the size of the piece to be
manufactured
1
PROCESS
2
The closed mold is placed in a furnace at a
temperature ranging between 300 and 350
°C where the polymer will melt or sinter. The
mold begins to rotate slowly around two
perpendicular axes placed across the center or
gravity of the piece. Rotary motion makes the
polymer cover the internal walls of the mold
in a relatively uniform war, hence creating a
hollow piece
3
Finally, the mold is left to cool down, and the
solid piece is unmolded
4 FINISHING
During the last stage of the process, the
rotomolded piece is trimmed, cleaned and
finished for use
5 SHIPPING
The rotomolded pieces are shipped according
to the delivery schedule and conditions
previously agreed on with the client in order
for the supplied materials to be available for
FEATURES AND
ADVANTAGES
•Strict compliance with size requirements.
•Strict compliance with production standards.
•Pieces may be manufactured in different
sizes and complex shapes thanks to a versatile
production process.
•Customizable wall thickness to meet the
client’s requirements.
•Pieces may be manufactured in different
customizable colors.
process.
CERTIFICATES
•ISO 9001:2008
QUALITY CONTROL
•Volume capacity control.
•Measurement of sun ray filtration.
•Torque control in lid.
•Inspection of sediment beds.
•Wall thickness control.

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ASSEMBLY
OF PRODUCTS

22
Several assembly parts of different products
are manufactured with multiple raw materials
such as copper, brass, steel, stainless steel,
and aluminum.
1 DIE-CUTTING
PROCESS
2 BRIGHT FINISHING
If required, a bright finish is given to the die-
cut assembly parts of the final product.
3 BOLTING
A great variety of screws is manufactured to
be subsequently mounted on other products.
Bolts, nuts, and screws are made of a copper-
iron alloy with a special weather-resistant
finish.
4 ASSEMBLY
The different parts (internally or externally
manufactured) are assembled in workshops
by qualified staff who use the necessary tools
according to the requirements of the final
product.
5 SHIPPING
The pieces are shipped according to the
FEATURES AND
ADVANTAGES
•Compliance with size requirements.
•Qualified staff.
•Proper tools and work areas according to the
process in question.
•Ensured compliance with production
standards.
•Permanent supervision during production
stages.
CERTIFICATES
ISO 9001:2008.
QUALITY CONTROL
Die-casting
•Size measurement of every piece.
Bright finishing
•Amount of chemicals.
•Time and temperature.
Bolting
•Size measurement of every piece.
Assembly
•Visual inspection.
•Separation of defective pieces.
•Performance of acceptance tests.
•Application of delivery protocols.
Shipping
•Visual inspection.
•Application of delivery protocols.

24
Iron-based pieces are received and inspected
before being prepared for pickling
1 MATERIAL RECEPTION
PROCESS
2 PICKLING
The pieces are degreased, washed, pickled
and rinsed to remove impurities and soften
their surface
3 FLUXING
The pieces are immersed in an aqueous
solution with zinc and ammonium salts at a
specific temperature in order to facilitate the
diffusion of zinc in the base metal of the pieces
4 GALVANIZING
The pieces are immersed in molten zinc to
create a corrosion-resistant layer of zinc and
iron around the pieces
5 FINAL INSPECTION
The quality of the zinc coating is verified
through visual inspection and physical tests.
7 SHIPPING
6 FINISHING
The metal pieces are finished in order to
remove superficial rough seams or scraps
FEATURES AND
ADVANTAGES
•Multiple sizes available
•Galvanizing of steel-made and cast pieces
•Variable speed according to requirements
•Flexible zinc-immersion time
•Manual and semi-automatic process
•Continuous process improvement to increase
productivity
CERTIFICATES
ISO 9001 2008
QUALITY CONTROL
•Acid concentration control
•Fluxing concentration control
•Molten zinc temperature control
•Immersion time control
•Verification of unit sizes
•Verification of coating thickness of each piece

WORLDWIDE SALES:
SUPPLY CONCEPTS, NORTH AMERICA
46 West. Jefryn Blvd
Deer Park, N.Y. 11729
Phone (631) 661-6915
Fax (631) 321-5662
SUPPLY CONCEPTS, MEXICO
Volcán Fujiyama 1997
El Colli Urbano
Zapopan Jalisco Mexico
CP 45070
Phone (52) 33- 2410 1201
Fax (52) 33 3770-2300
SUPPLY CONCEPTS, EUROPE
B.S.R Tower 1, floor 11, Ben Gurion St. 2
Ramat Gan 52573, Israel
Phone 972732424530
Fax 972 3 941 5636
www.supplyww.com ○ www.iusa.mx

IUSA MFG OVERVIEW

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