A commercial vehicle manufacturer in Eastern India, supported by a captive Grey and Ductile Iron foundry, partnered with MPM to resolve recurring sand fusion and casting rework using Lustron, the engineered green sand additive. Through controlled granularity and anti-scabbing chemistry, the plant achieved a near-complete reduction in sand fusion defects while lowering additive cost per tonne.
Commercial Vehicle Manufacturer, Eastern India
Automotive – Medium & Heavy Commercial Vehicles
Sand Fusion & Scab Rejection Reduction
Lustron Green Sand Additive
Trial-to-Production Validation
The facility operates high-speed molding lines and modern melting capacity, producing one truck every five minutes against an annual capacity of over 60,000 vehicles. At this volume, even small inefficiencies in additive performance translate into significant rework and cost. The objective was to reduce sand fusion and scab-related rejections without disrupting the existing high-speed molding process.
Following the introduction of Lustron, formulated to VM ≥45.0%, Ash ≤5.0%, and 80% minimum passing at 0.212mm:
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