Green Sand: Art to Analytics
SANDMAN® DigiSMART organizes, stores, validates, analyzes, and leverages your foundry's molding sand data legacy for molding process optimization, using prescriptive and predictive data analytics, enabling SANDMAN is a globally patented, cloud-based data analytics platform built to optimize the entire green sand foundry system. It goes beyond reporting by delivering real-time, actionable guidance that keeps sand preparation, moulding, and rejection control running at peak efficiency, from sand prep to molten metal pouring.
SANDMAN was built to close a gap most foundries share: sand properties are inconsistent, and rejections rarely get correlated back to consumption in real time. Founder Deepak Chowdhary, with 40+ years in the foundry industry, envisioned a data-driven transformation of the foundry ecosystem, believing that real-time data and advanced analytics could fundamentally change the way foundries operate.
The scale of the problem is well documented. Foundries typically suffer 2% to 20% casting defects, and because those rejections repeat, so do the losses. On an entry-level foundry producing 24,000 tons a year, the cost of just a 1% molding sand rejection runs approximately $225,000 annually. A 10% cut in additive consumption through process optimization saves roughly another $110,000 a year.
Repetitive rejections trace back to four connected blind spots:
Traditional foundry operations rely on experience-based decisions and manually recorded data that is often uncaptured, disconnected from rejection outcomes, and slow to analyze.
SANDMAN runs on a simple working principle: foundry data (sand properties, rejections, additives, component master) feeds a grouping algorithm, which routes each group through predictive and prescriptive analytics to define the optimal operating condition. The result is measurable: optimized system performance, optimal additive consumption, and lower rejection.
High Influence, SANDMAN’s predictive analytics module, analyzes multivariate correlations across sand properties to identify which parameters most influence casting rejections at any point in time, then gives control guidance to minimize them. SANDMIX, SANDMAN’s prescriptive analytics engine, takes that a step further, prescribing near-precise “dose-by-need” additive quantities instead of relying on fixed dosing.
Analyze historical and real-time process data to identify influential sand parameters and correlate them with casting defects for consistent process performance.
Delivers dynamic root cause analysis within 5 minutes, using advanced statistical tools and Fishbone/Ishikawa diagrams to compare sand properties between good and poor performance periods in near real time.
Key Highlights
Forms multivariate correlations across sand properties to identify the parameters most influential on casting rejections, then provides control guidance to minimize them.
Key Highlights
Prescribes near-precise, dose-by-need additive quantities (bentonite, fresh silica sand, LCA, and more) for each new pattern group, replacing fixed dosing with variable, multivariate analytics.
Key Highlights
From a real-time dashboard and smart alerts to SPC tools and root cause analysis, SANDMAN® DigiSMART provides a complete digital ecosystem for green sand process management.
Fishbone/Ishikawa-based root cause analysis that pinpoints problem areas within about 5 minutes
Captures sand, casting pattern, and process data via desktop, mobile, and PLC/SCADA integration for near real-time accuracy
Logs system changes and process changes on the shop floor, institutionalizing foundry experience instead of losing it
Smart alerts via email, WhatsApp, SMS, and in-app notification for security, process, performance, and analytics deviations
Line charts, run charts, process control charts, and process capability metrics for real-time statistical process control
Business intelligence dashboard showing production, rejection, and sand status metrics with powerful filters and exportable charts
Sandman Brochure
Information - English - 06-08-2026 - 22.07 MB
MPM Product Brochure
Information - English - 07-07-2026 - 52.72 MB
The SANDMAN team is ready to help your foundry move from reactive to proactive green sand control, reducing sand-related repetitive casting rejections and additive consumption.
