Metal foundry for precision castings in sand casting and permanent mould casting using aluminium, copper, brass and zinc alloys.
Karl Kaldenberg GmbH & Co. KG
HeiligenhausNew on Amplifa
About Karl Kaldenberg
The metal foundry Karl Kaldenberg GmbH & Co. KG has been producing precision castings in sand casting and permanent mould casting since 1930. The family business from Heiligenhaus, now run by the third generation, produces castings from almost all aluminium and copper-base alloys, including aluminium castings, brass castings, bronze castings, copper castings, gunmetal, special brass and aluminium bronze. Production is carried out as hand casting for individual parts and as machine casting using pattern plates for small and large series; in addition, low-pressure permanent mould casting is offered exclusively for aluminium alloys, along with CNC machining, surface treatment including decorative anodised surfaces for sand castings, and prototype production. The castings are produced on a production area of more than 6,000 m² and, at the customer's request, are machined and delivered ready for installation. Customers include, among others, rail vehicle construction, special vehicle construction, mechanical and plant engineering, the electrical industry, the mining industry and renewable energy technology. The entire production is certified to ISO 9001:2015.
- Site
- Heiligenhaus
- Processes
- Sand casting, Permanent mould casting, Low-pressure permanent mould casting, CNC machining (mechanical machining of castings), Surface treatment incl. decorative anodising (sand castings with anodised surfaces), Prototype production, Design and development of new castings / production according to specification (model, sample,, Brinell hardness testing, spectral analyses, endoscopy, measurement of electrical conductivity,
- Materials
- G-AlSi12, GK-AlSi12, G-AlSi12 (Cu), GK-AlSi12 (Cu), G-AlSi10Mg, GK-AlSi10Mg, G-AlSi10Mg (Cu), GK-AlSi10Mg (Cu)
- Certificates
- ISO 9001:2015, ISO 9001
- Founded
- 1930
- Employees
- >60
- Industries
- Special vehicle construction, Rail vehicles, Mechanical engineering, Engine construction, Electrical and electronics industry, Plant engineering
- 01
Design and development of new castings
- 02
Production of casting moulds/models in own workshops
- 03
Prototype production
- 04
Hand casting and machine casting (sand casting, permanent mould casting,
- 05
CNC machining
- 06
Surface treatment incl. decorative anodising
- 07
Assembly
- 08
Delivery ready for installation
Locations
Heiligenhaus
DEProduction and administration
- Lot size
- Individual parts (hand casting) to small and large series (machine casting)
- Materials
- Aluminium, copper, brass and zinc alloys
- 5 Kurtz low-pressure permanent mould casting machines (incl. ND AL13-13 TC, ND AL7-5TC)
- Göllner permanent mould casting machines (incl. KGA 400, KGA 1500 E, KGA 10)
- Budde permanent mould casting machines (incl. OHB-2)
- MBS permanent mould casting machine KM4
- Kurtz tandem permanent mould casting machine AK 10
- Kurtz gravity permanent mould casting machine AL 13-13 SC
- CNC machines for mechanical machining
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Sand castingCasting | – | – | – | Individual parts (hand casting process) – Small or large series (machine casting) | Copper, Gunmetal, Bronze, Brass, Special brass, Aluminium bronze, Zinc alloys, all common aluminium alloys |
| Permanent mould castingCasting | excellent surface quality | – | – | – | all common aluminium alloys, Brass, Special brass, Zinc alloys |
| Low-pressure permanent mould castingCasting | – | – | – | – | Aluminium alloys (exclusively) |
| CNC machining (mechanical machining of castings)Machining | – | – | – | – | – |
| Surface treatment incl. decorative anodising (sand castings with anodised surfaces)Surface | – | – | – | – | Aluminium |
| Prototype productionCasting | – | – | – | – | – |
| Design and development of new castings / production according to specification (model, sample,Engineering | – | – | – | – | – |
| Brinell hardness testing, spectral analyses, endoscopy, measurement of electrical conductivity,Testing | – | – | – | – | – |
| Assembly (e.g. turntable including mechanics and assembly, delivery ready for installation)Assembly | – | – | – | – | – |
| Welding-in of castings (e.g. filler opening welded in)Joining | – | – | – | – | – |
21 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Low-pressure permanent mould casting machine | Kurtz ND AL13-13 TC | – | movable 1.800 x 1.610, fixed 1.620 x 1.620 | – | Heiligenhaus |
| Low-pressure permanent mould casting machine | Kurtz ND AL13-13 TC (2nd system) | – | movable 1.800 x 1.610, fixed 1.620 x 1.620, plate distance 500 | – | Heiligenhaus |
| Low-pressure permanent mould casting machine | Kurtz ND AL7-5TC | – | 1.050 x 850, plate distance 1.100 | – | Heiligenhaus |
| Low-pressure permanent mould casting machine | Kurtz ND AL7-5TC (2nd system) | – | 1.050 x 850, plate distance 500 | – | Heiligenhaus |
| Low-pressure permanent mould casting machine (new machine since May 2026) | Kurtz Low-pressure system | 1 | – | 2026 | Heiligenhaus |
| Permanent mould casting machine, gravity | Göllner HD-2 | – | 400 x 300 / 200 | – | Heiligenhaus |
| Permanent mould casting machine, gravity | Göllner HD-2 | – | 500 x 400 / 200 / 300 | – | Heiligenhaus |
| Permanent mould casting machine, gravity | Göllner KGA 400 | 2 | 800 x 600 / 300 | – | Heiligenhaus |
| Permanent mould casting machine, tilting machine | Göllner KGA 1500 E | 1 | 1.200 x 1.200 / 200 to 1.000 | – | Heiligenhaus |
| Permanent mould casting machine, gravity | Göllner | 1 | 600 x 500 / 150 / 200 / 300 | – | Heiligenhaus |
| Permanent mould casting machine, tilting machine | Göllner KGA 10 | 1 | 600 x 800 | – | Heiligenhaus |
| Permanent mould casting machine, gravity | Göllner KGA 400 | 1 | 600 x 600 | – | Heiligenhaus |
| Permanent mould casting machine, gravity | Budde | 5 | 800 x 600 / 150 / 300 | – | Heiligenhaus |
| Permanent mould casting machine, gravity | Budde OHB 2 | 1 | 1.000 x 600 / 300 | – | Heiligenhaus |
| Permanent mould casting machine, gravity | Budde OHB-2 | 1 | 800 x 600 / 150 / 300 | – | Heiligenhaus |
| Permanent mould casting machine, gravity | Budde OHB-2 | 2 | 600 x 400 / 120 / 240 | – | Heiligenhaus |
| Permanent mould casting machine, tilting machine | MBS KM4 | 1 | 1.000 x 1.000 / 300 / 550 / 750 | – | Heiligenhaus |
| Permanent mould casting machine, gravity | Krepela | 1 | 500 x 300 / 200 | – | Heiligenhaus |
| Permanent mould casting machine, tandem gravity | Kurtz AK 10 | 1 | 600 x 600 / 100 / 300 / 500 | – | Heiligenhaus |
| Permanent mould casting machine, tilting machine | Budde | 3 | 800 x 600 / 200 / 380; 600 x 400 / 200 (2 units) | – | Heiligenhaus |
| Permanent mould casting machine, gravity | Kurtz AL 13-13 SC | 1 | 600 x 600 | – | Heiligenhaus |
Additional services
Reference customers
Quality
The quality management system is certified to ISO 9001:2015 by DMSZ. Testing uses equipment for measuring, gauging, endoscopy, spectral analyses, Brinell hardness testing, measurement of electrical conductivity and testing of mechanical properties.
| Evidence | Heiligenhaus |
|---|---|
| ISO 9001 |
History
- 1930
Founded by Karl Kaldenberg as a sand foundry for brass castings.
- 1945
Resumption of operations as a sand foundry for copper and light metal alloys after war-related closure.
- 1959
Death of company founder Karl Kaldenberg.
- bis 1963
Continuation of the business by Elisabeth Kaldenberg.
- 1963
Takeover by Karl Hans-Peter Kaldenberg.
- 1965/1966
Relocation to today's site in Heiligenhaus with production area of approx. 600 m² at that time.
- 1980
New construction of around 700 m² of production area for the permanent mould casting plant.
- 2008
Takeover by Karl Joachim Stephan Kaldenberg.
- 2010
New construction of the administration and shipping building.
- 2021
Commissioning of a photovoltaic system with up to 99.75 kWp.
- 2022
Expansion of the production area by an additional 1.000 m².
- 2023
Expansion of the production facilities to a total of 5 low-pressure permanent mould casting machines.
- 2026
Commissioning of a new Kurtz low-pressure system; modernisation of the Kurtz and MBS permanent mould casting machines (type KM4) by NEMETecH.