DENİZCİLER DÖKÜMCÜLÜK SAN. VE TİC. A.Ş.

COMPANY PRESENTATION 2015

About Us :

Founded in 1978

• Total production capacity app. 24.000 Tons/year.

Total area 25.000 sqm., covered production facilities14.000 sqm.

200 qualified employees.

Our main activity is;

the production of gray and ductile iron castings. their machining heat treatment, coating and hot dip galvanizing.

Single Part weights; from 0,5 kg./piece to 15000 kg./piece

Various approvals including ISO 9001,

Where we are:

Corporate Information :

Full Name & Address:

Legal Form :

Establishment Date :

Tax Registration Office :

Paid Capital :

Memberships :

DENİZCİLER DÖKÜMCÜLÜK SANAYİ VE TİCARET A.Ş.

Kutlu Aktaş Cad. No:23 ALOSBI 35800 Aliağa IZMIR/TURKEY

Incorporated Company

03.12.1981

Hasan Tahsin Tax OfficeTax Id. Number: 292 000 3925

10.000.000 Turkish Liras

Aegean Chamber of Industry No: 10408Aliağa Chamber of Trade No : 3964

Our Staff :

By Position Number

Manager 7

Administration 20

Chief 1

Foreman 13

Master 8

Direct Workers 161

Total : 210

By Education Number

University Graduate (Engineer) 13

University Graduate (Others) 14

Vocational College Graduate 7

Technical High School Graduate 30

High School Graduate 18

Others 128

Total : 210

Production Processes :

Pattern Design & Simulation

• The CAD/CAM software TOPSOLID , used for designing the patterns, enables us to make 3D Models of the parts to be casted and also to determine the part weights.

• 3D Modelling is also the starting point for our casting simulation program QUIKCAST.

• Before the actual casting process, the possible problems that may arise from the pattern design or the casting parameters are determined and the corrective actions are taken in advance to resolve these identified problems.

• The optimised casting parameters and the molding design leads to minimized quality problems , increasing our production efficiency.

• These optimised parameters are than integrated into product sheets to maintain the best quality during the serial production.

• The prepared samples will be checked with 3D Laser scan Faro Arm. The scanned data is checked with the original Cad data received from customer.

Pattern Production

• Being fully aware of the fact, that quality castings require quality patterns, we attach great importance to pattern production with accurate dimensions and tolerances.

• Depending on the required lifetime and the selected moulding line, patterns are made accordingly of wood, aluminium, iron or polystrene.

• Our well equipped pattern shop with CNC Centers and our experienced team enables us to fulfill our customers’ requirements in terms of new patterns or modifications within favourable lead times.

• The patterns are registered in our ERP system and stored properly in ourwarehouse after final controls for easy access and maintenance.

Sand Preparation

•Our fully automatic sand preparation plants are PLC controlled and enable us to achieve best possible results in terms of surface qualityfor our castings.

• For sustainable sand quality, mix preparation is controlled at every batch for compactability, green strength and moisture.

•Furthermore, samples are also manually taken and cross checked in our quality lab to ensure that the required specifications are met.

• 1 x Simpson Speedmüller 85B Sand Mixer 60 Tons/Hour

• 1 x Webac Müller Sand Mixer 50 Tons/Hour

• 2 x Hartley Sand Control System

• Besides green sand system, we also utilise furan system for our semi-automatic moulding line, as well as for hand moulding.

• Omega Spartan 2 Sand Mixer (10 Tons/Hour) with cooling and reclamation system.

Core Making

• According to the requirements of the castings demanded by our customers, we utilise different kinds of base materials for the production of cores.

• Following materials are used for core production.

• CO2 Sand

• Furan Resin Sand

• Chrome Ore Sand

• Shell Moulding Sand

• Utilised machines are;

• 3 x 80 lt capacity cold box machine (CO2 + Carbophen)

• 1 x 60 lt capacity cold box machine (CO2 + Carbophen)

• 4 x 25lt capacity cold box machine (CO2 + Carbophen)

• 6 x 5lt. capacity cold box machine (CO2 + Carbophen)

• 4 x 2lt. capacity shell and hot box core machine

Moulding

•The molding process is rather diversified and depends on thedesign , complexity, weight and accuracy of the casting.

• One of our three full automatic molding lines for parts up to 90 kg single part weights is our DISA MATCH 24 x 28 (Horizontal)

• 120 Moulds/ Hour capacity

• Mould dimensions 613 mm x 713 mm x 500 mm

• 2 x Hunter HMP 20 x 24 automatic moulding lines.

• 100 Moulds/ Hour capacity

• Mould dimensions 508 mm x 613 mm x 400 mm

• Single part weights up to 90 kg.

• Automatic pouring and cooling lines.

• 1 x Semi-automatic (flaskless) molding line with rollover, operating with furan resin system (OMEGA, UK)

• Spartan 2 Sand Mixer 10 Tons/Hour (OMEGA, UK)

• Single part weights up to 350 kg.

• Mould sizes 1250 mm x 1800 mm x 900 mm

Hand Moulding

• Prototypes, castings not suitable to our moulding line in terms of part weight and dimensions, as well as parts with smallerquantities are produced with this method.

• To this end we have flasks in various dimensions. Flasks with sizes up to 4000 mm x 4000 mm are available.

• Single part weights up to 10000 kg for ductile iron and up to 15000 kg for gray iron.

Melting & Pouring

• Our melting capacity is 14,2 Tons/Hour,

• Following induction furnaces are operative at our foundry;

1 x 7200 kg/hr 4250 kw medium frequency furnace

1 x 4500 kg/hr 2750 kw medium frequency furnace

1 x 1500 kg/hr 800 kw medium frequency furnace

1 x 1000 kg/hr 600 kw medium frequency furnace

Fettling

• After cooling down for specified time periods, the in gates, feeders, as well as the risers of the casted parts are removed. Than the residual molding sands are removed in suitable shot blasting machines and parts are subjected to quality control to determin their status.

• The castings approved by our quality staff are than forwarded to the work stations, where they are grinded for their end rough dimensions.

• For these operations we utilise the following equipments;

• 1 x continuous hook type shot blasting machine (2400 mm x 1500 mm x 1500 mm - 10 Tons/hour)• 1 x tumble type shot blasting machine ( 10 Tons/hour)• 3 x hook type shot blasting machines (1400 mm x 1500 mm x 1500 mm 2 Tons/hour)• 3 x tumble type shot blasting machines ( 1000 kg / hour - ø 600 mm)

•10 x wheel grinding machines - 600 mm diameter, 60m/sec • Various air grinding tools

•2 Koyama 6 axis automatic grinding machines

Machining

• The parts casted in our foundry are delivered as machined at customers’ request.

• Following machinery is in use in our machining shop

• Machining is also outsourced from regional machining shops in case of large order quantitites.

• 1 x Vertical CNC 3 Axis (Quaser)x= 1270 mm , Y= 700 mm , Z= 600 mm

• 1 x Vertical CNC 3 Axis (Ajan)x= 900 mm , Y= 700 mm , Z= 400 mm

• 1 x Vertical CNC 3 Axis (Ajan)x= 700 mm , Y= 700 mm , Z= 300 mm

• 1 x Horizontal CNC Lathe (Takisawa)ø 450 mm, Y= 762 mm.

• 1 x Conventional Latheø 660 mm, Y= 2500 mm.

• 1 x Conventional Lathe (Tos)ø 520 mm, Y= 2000 mm.

• 1 x conventional Latheø 660 mm, Y= 3000 mm.

• 8 x Column Drilling Machines ø 30 mm

Quality

Microstructure Analysiswith Microscope to magnify 1500X

Chemical Analysis with spectrometer • 1 x OBLF for 15 elements• 1 x OBLF for 18 elements

Tensile Testing,Compression Testing,Bending TestingCapacity 20 tons

FARO 3D Measuring Arm/ Faro Gage Lazer Scan

hardness tester 3000 Kg ,Ball Ø10 mm

Ultrasonic Inspection (Karl Deutsch)Penetration 120 mm

Coating

• According to customer specifications the primer coating is perforned at our dipcoating line.

• Hot dip galvanising is also performed in-house.

Packing & Delivery

• The suitable delivery method is determined mutually with our customers .

• Labelling is done according to customer specifications.

• According to their weight and dimensions, parts are delivered on Euro pallets, in wooden boxes and crates, covered with strectch film.

• Loads are secured properly to avoid any kind of transport damage.

For machined parts suitable anti-corrosion materials are used.

Industries Served :Machine Building Industry

Part Name Reduction Housing Material GG 25Weigt 12,5 kgDimensions 200 x 180 x 150

Part Name Gearbox CoverMaterial GGG 50Weigt 41 kgDimensions 480 x 530 x 150

Part Name Gearbox Material GGG 70Weigt 160 kgDimensions 470 x 560 x 440

Part Name Shaft CoverMaterial GG 25Weigt 60 kgDimensions 800 x 450 x 500

Part Name ConnectorMaterial GGG 60Weigt 14 kgDimensions 400 x 200 x 310

Part Name SupportMaterial GG 20Weigt 21 kgDimensions 450 x 300 x 200

Part Name Gearbox Body & Cover Material GG 20Weigt 16 kg – 8 kgDimensions 250 x 200 x 410

Part Name Compressor Cylinder HeadMaterial GG 25Weigt 8 kgDimensions 400 x 200 x 100

Part Name Reduction HousingMaterial GGG 50Weigt 9 kgDimensions 300 x 200 x 140

Part Name 90° Shaft CoverMaterial GG 40Weigt 45 kgDimensions 700 x 600 x 500

Part Name Gearbox CoverMaterial GG 25Weigt 125 kgDimensions 1200 x 1000 x 450

Part Name Air Valve HousingMaterial GG 25Weigt 12 kgDimensions 250 x 400 x 120

Pump & Valve Industry

Part Name Pipe CouplingMaterial GGG 45Weigt 32 kgDimensions DN 300

Part Name Water Pump BodyMaterial GG 25Weigt 32 kgDimensions 700 x 600 x 240

Part Name Cooling Compressor BodyMaterial GGG 25Weigt 120 kgDimensions 1000 x 1000 x 650

Part Name Pump CasingMaterial GG 25Weigt 70 kgDimensions 553 x 620 x 220

Part Name ImpellerMaterial GG 25Weigt 15 kgDimensions Ø 300

Part NameMaterialWeigt Dimensions

Part Name Tapping Saddle Material GGG 40Weigt 45 kgDimensions 500 x 225 x 180

Part Name Valve BodyMaterial GGG 40Weigt 250 kgDimensions DN 700

Part Name Actuator Housing Material GGG 50Weigt 590 kgDimensions 700 x 500 x 550

Part Name Adaptor BodyMaterial GG G 40Weigt 8 kgDimensions DN 150

Part Name ImpellerMaterial GG 25Weigt 15 kgDimensions Ø 300

Part Name Slide ClampMaterial GGG 40Weigt 10 kg Dimensions 250 x 100 x 150

Agricultural Machinery Industry

Part Name CoverMaterial GGG 50 Weigt 18 kgDimensions 300 x 200 x 240

Part Name Gearbox CoverMaterial GG 25Weigt 28 kgDimensions 500 x 350 x 180

Part Name BracketMaterial GGG 40Weigt 12 kg – 15 kgDimensions 450 x 350 x 200

Part Name Shaft ExtensionMaterial GGG 40Weigt 40 kgDimensions 450 x 200 240

Part Name Shaft CoverMaterial GGG 50Weigt 9 kgDimensions 300 x 200 x 140

Part Name Loading ArmMaterial GGG 40Weigt 14 kgDimensions 400 x 200 x 150

Civil Engineering Industry

Part Name Tube FittingsMaterial GGG 40 Weigt 0,5 kg – 6 kg

Dimensions ¾”-2”

Part Name Manhole and CoverMaterial GG20 - GGG 40Weigt 11 kg – 18 kgDimensions 400 x 400 x 400

Some of Our References :

ADDRESS: KUTLU AKTAŞ CADDESİ NO:23 ALOSBİ ALİAĞA35800 İZMİR - TURKEY

TEL: 00 90 232 621 55 02

FAX: 00 90 232 621 55 04

WEB: www.denizcast.com

EMAIL: info@denizcast.com

THANKS FOR YOUR ATTENTION

Contact Informations :