Unique Conveyor System Installed at Electron Corporation
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Increased Foundry Production Capacity by Over 50% with Serpentix Conveyor Systems
Location: Littleton, Colorado
Electron Corporation of Littleton, Colorado became the first American foundry to use Serpentix conveyors as part of its high-pressure molding system. By integrating two Serpentix conveyors with a Herman Moldmaster, the system enabled continuous sand handling through steep inclines, tight turns, and underground routing. The result was a significant boost in production capacity—potentially doubling mold output to 120 per hour and increasing overall casting output by more than 50%.
Challenges
Serpentix Solutions
One conveyor hauls molding sand across two inclines and multiple turns, side-discharging into an 85-ton hopper
Second conveyor operates underground, recovering spill sand via a 113-ft belt system and integrating it with the existing sand mulling process
Eliminated the need for three conventional conveyors and related transfer equipment
Results
Enabled a 120 molds/hour production rate—up to 1M lbs/week output
Seamless integration with existing systems
Reduced capital expenses through modular design efficiency
Case Study: Electron Corporation – Grey and Ductile Iron Foundry
Industry: Manufacturing (Metal Casting / Foundry Operations)
Location: Littleton, CO
System Used: Dual Serpentix Conveyor Systems
Application: Mold sand delivery to high-pressure molding unit (Herman Moldmaster); spill sand recovery and reintegration into shake-out system
Challenges
Limited floor space for mold system integration
Need for precise sand transport and recovery without spillage or rollback
Complex routing including multiple inclines and 90° turns
Solution Highlights
One conveyor hauls molding sand across two inclines and multiple turns, side-discharging into an 85-ton hopper
Second conveyor operates underground, recovering spill sand via a 113-ft belt system and integrating it with the existing sand mulling process
Eliminated the need for three conventional conveyors and related transfer equipment
Results
Enabled a 120 molds/hour production rate—up to 1M lbs/week output
Seamless integration with existing systems
Reduced capital expenses through modular design efficiency
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