Inhouse outsourcing for foundries: fettling, core making, machining and surface technology for castings up to 80 t
ao Giessereiservice GmbH & Co. KG
Ransbach-Baumbach (DE)New on Amplifa
About ao Giessereiservice
ao Giessereiservice GmbH & Co. KG is part of the ao Group based in Ransbach-Baumbach and, under work contracts, takes over complete production processes at foundries throughout Germany. As an inhouse outsourcing partner, the family-owned company integrates itself into existing structures and takes responsibility for clearly defined production areas – from knock-out of castings, through core making and blasting, to fettling, machining (turning, milling, drilling, fitting), painting, galvanizing and concrete casting, as well as packaging and warehouse services. Castings made of iron, steel and bronze of all sizes up to a component weight of 80 tonnes are processed. In addition to fettling robots with CNC control, high-frequency grinders, grinding stands, swing-frame cutting machines, blasting systems and endoscopes are used. Customers include companies from the energy and drive technology, mechanical and plant engineering, rail technology, pump and hydraulics industry, engine manufacturing, turbine construction, shipbuilding and wind energy sectors. The company is certified to DIN ISO 9001 and is led by founder Aziz Ortakaya.
- Site
- Ransbach-Baumbach
- Processes
- Knock-out of castings (knock-out stations, separation of moulding material and casting), Core making (core production, core assembly, core coating), Blasting (centrifugal blasting, intensive blasting), Fettling (removal of gate stubs, feeders, burrs, fine fettling), Fettling with fettling machine/robot (grinding, cutting, deburring, CNC-controlled), Machining (cutting: turning, milling, drilling, fitting), Painting (spray process, dipping process, primer, topcoat, protective coating), Galvanizing (corrosion protection)
- Materials
- Iron (cast), Steel, Bronze, Moulding sand, binders, water- and alcohol-based core washes, Galvanizing, Concrete casting
- Certificates
- ISO 9001:2015, ISO 9001
- Founded
- 1995
- Industries
- Foundry industry, Energy & drive technology, Vehicle machinery construction, Agricultural machinery, Mechanical & plant engineering, Rail technology
- 01
Knock-out of castings
- 02
Core making
- 03
Blasting
- 04
Fettling (manual/robotic)
- 05
Machining (turning, milling, drilling, fitting)
- 06
Painting/Galvanizing
- 07
Concrete casting
- 08
Inspection technology
- 09
Packaging & warehouse services
- 10
System booking
Materials & Processes
Iron (cast)
Main material of the processed castings, e.g. in blasting and fettling.
Steel
Steel castings are blasted, fettled and machined.
Bronze
Bronze castings are treated gently in the blasting process.
Moulding sand, binders, water- and alcohol-based core washes
Core making materials for internal and external cores.
Galvanizing
Corrosion protection of castings before or independently of painting.
Concrete casting
Manual and machine concreting, e.g. for manhole covers.
Locations
Ransbach-Baumbach
DEAdministrative and group site; external fettling shop (ao Guss-Oberflächentechnik)
- Part weight / size
- up to 80 t component weight
- Materials
- Iron, steel, bronze
- Fettling robots (CNC-controlled)
- Core shooting machines
- Blasting systems/intensive blasting systems
- Bosch/Fein high-frequency grinders
- REMA grinding stands
- Swing-frame cutting machines
- Diamond tools
- CNC lathes
- CNC milling machines
- Dust extraction systems
- Endoscopes (rigid/flexible)
Components & Services
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Knock-out of castings (knock-out stations, separation of moulding material and casting)Casting | – | – | – | – | Castings (iron, steel, bronze derivable) |
| Core making (core production, core assembly, core coating)Casting | – | – | – | – | Moulding sand, Binders, Water-based core wash, Alcohol-based core wash |
| Blasting (centrifugal blasting, intensive blasting)Surface | – | – | – | – | Iron, Steel, Bronze |
| Fettling (removal of gate stubs, feeders, burrs, fine fettling)Surface | – | – | 80 t | – | Castings |
| Fettling with fettling machine/robot (grinding, cutting, deburring, CNC-controlled)Surface | – | – | – | – | Castings |
| Machining (cutting: turning, milling, drilling, fitting)Cutting | – | – | – | – | Castings |
| Painting (spray process, dipping process, primer, topcoat, protective coating)Surface | – | – | – | – | Castings |
| Galvanizing (corrosion protection)Surface | – | – | – | – | Castings |
| Concrete casting (manual and machine concreting, e.g. manhole covers)Assembly | – | – | – | – | Castings, Concrete |
| Inspection technology (final inspection, endoscopy, visual inspection, mirror inspection)Testing | – | – | – | – | Castings |
| Packaging & warehouse services (shipping preparation, corrosion-protected storage)Assembly | – | – | – | – | Castings |
| Machine and plant cleaningSurface | – | – | – | – | – |
| System booking (booking finished parts into the production system)Assembly | – | – | – | – | – |
| Consulting (process optimization, workplace design, cost control)Engineering | – | – | – | – | – |
| Inhouse outsourcing / work contracts at foundries (including melting operation/charging, handCasting | – | – | – | – | – |
11 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Fettling robots (CNC-controlled) | – | – | – | – | Customer foundries (inhouse) |
| Core shooting machines | – | – | – | – | Customer foundries (inhouse) |
| Blasting systems / intensive blasting systems | – | – | – | – | Customer foundries (inhouse) |
| High-frequency grinders | Bosch / Fein | – | – | – | Customer foundries (inhouse) |
| Grinding stands | REMA | – | – | – | Customer foundries (inhouse) |
| Swing-frame cutting machines | – | – | – | – | Customer foundries (inhouse) |
| Diamond cutting tools | – | – | – | – | Customer foundries (inhouse) |
| CNC lathes | – | – | – | – | Customer foundries (inhouse) |
| CNC milling machines | – | – | – | – | Customer foundries (inhouse) |
| Dust extraction systems | – | – | – | – | Customer foundries (inhouse) |
| Endoscopes (rigid and flexible) | – | – | – | – | Customer foundries (inhouse) |
Additional services
Quality
Final inspection includes checking surface condition, casting defects, sand adhesions, pickling damage and geometric deviations using rigid and flexible endoscopes as well as visual and mirror inspection. The quality management system is documented to DIN EN ISO 9001 and verified through internal and external audits.
| Evidence | Ransbach-Baumbach |
|---|---|
| ISO 9001 |
History
- 1980
Aziz Ortakaya starts as a fettler at Buderus Guss; in 1992 he becomes foreman of mechanical processing.
- 1995
Self-employment in Nassau; taking over fettling work for companies in the region.
- 2005
Renaming to ao Personaldienstleistungen e.K., expansion throughout Germany, membership of iGZ.
- 2015
Relocation to Ransbach-Baumbach; founding of ao Guss-Oberflächentechnik GmbH with its own fettling shop.
- 2018
Foundation of the ao Group with ao Giessereiservice GmbH & Co. KG, ao Giessereidienstleistungen e.K. and ao Guss-Oberflächentechnik GmbH.
- 2019
Certification to DIN ISO 9001.