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Simpson Multi-Mull Continuous Mixer For Foundry Applications

Foundries producing medium to very large volumes of castings on high-speed molding lines demand large volumes of prepared sand and maximum productivity from the sand plant. The Simpson Multi-Mull is specifically designed to provide medium to very large volumes of high-quality molding sand on a continuous basis and utilizes the same effective mulling technique as the Simpson Mix-Muller.
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Delivers up to 50% more hourly production than two batch mixers of equivalent diameter.

Description

Medium-speed, high-intensity, muller-type mixer for continuous operation.

Application

Medium to very large sized sand preparation systems seeking consistency high volumes and maximum efficiency.

Features

– Continuous mixing with back blending
– Maximum energy efficiency
– Controlled retention for consistency

“With our particular mold line system, we need all the effective bond we can get. We need high green strength characteristics to make it work. That’s where the Multi-Mull does its job, giving us twice the working bond strength of our old high speed batch system.” – Iron Foundry

The Most Advanced Sand Preparation Tool for Medium to Large Foundries

As molding lines get larger and faster, modern foundries require larger volumes of high quality molding sand produced at the lowest total cost. Foundries that use batch mixers experience downtime when they do not have an adequate supply of sand. In addition, these batch mixers produce non-uniformity in the molding sand which negatively impacts the quality of castings.

Imagine if …

  • Your total daily requirement of sand could be mulled in one big batch, stored in a sealed bin and fed to the system only as required.
  • The sand properties of your last mold of the day could be as consistent as possible to the first mold that day.
  • The above could happen primarily because all sand variables are cancelled out.
Continuous Mulling - The Ideal Situation

The Simpson Multi-Mull® is a medium speed, high intensity continuous mixer that is like no other. The synchronized dual muller and overlapping dual plow design enables sand and additives to be circulated and recirculated in a figure 8 movement within the Multi-Mull where they receive maximum exposure to mulling action before final discharge through a modulating door.

The Multi-Mull gives you an advantage over your competitors by:

  • Delivering a continuous supply of sand, on-demand
  • Consistently providing discharged sand of superior quality and uniformity
  • Producing high quality molding sand at a lower cost than any other solution
  • Protecting margins through lower energy consumption
  • Wasting no operating time on batching, charging, discharging, pre-mull dispersion or wetting of bond
  • Requiring far fewer system components Example: (1) Multi-Mull = 23 components vs. (2) Small Batch Mullers = 85 components
  • Lowering installation cost and reducing maintenance
  • Reducing profit-robbing downtime

“During the last 40 years, I have built foundries across the country. Of the various muller that I have seen, Simpson Multi-Mull not only looks the best, its performance is the best. [In one company alone]… I have installed 5 of them. And they’re still going strong. – Iron Foundry

Efficiency Makes You More Competitive

For high-volume, high-quality, cost-effective casting production, the Simpson Multi-Mull is the best solution. This technology produces larger volumes of molding sand at a lower cost of installation and operation than any other mixer in the world.

Increasing Productivity In Limited Spaces

Foundries have the unique ability to increase productivity of their sand, reduce wear parts, and maintain the current footprint by converting from batch systems to continuous with the Simpson Multi-Mull. Here is an example:

Large DISA/Iron Foundry–

  • 6x 100B-250 Simpson Speedmullors
  • 6x Simpson Hartley Controllers and 90Mk2 Bond Dosing Systems
  • 2,720 kg @ 120s cycle time = 82 t/h x 6 = 492 t/h sand preparation
  • 1,500 total HP (1,100 kW)
  • 328 t/HP

New Sand System –

  • 4x #26G-400 Simpson Multi-Mulls
  • 4x Simpson Hartley Controllers and BAS Bond Dosing Systems
  • 8,845 kg @ 150s retention time = 212 t/h x 4 = 848 t/h (+356 t/h)
  • 1,600 total HP (1,175 kW)
  • 53 t/HP (61% more than batch)
  • Reducing components from 85 for 2 Speedmullor batch systems to 23 components for one Multi-Mull
  • Reducing controllers and bond dosing from 6 to 4

What Customers's Have To Say

“Compared to a batch muller of the same size, the continuous muller is twice as good. We would need two 200 hp batch mullers to handle the same amount of sand.” – Iron Foundry

“[Our Simpson Multi-Mull] keeps the sand down on the pan for less heat build-up and less energy loss, and its continuous mulling action gives us a more consistent mix. It’s doing such a superb job…” – Iron Foundry

“Maintenance on the 22G is down 40% over our batch unit experience.” – Iron Foundry

Related Products: 

Simpson Technologies first introduced the concept of the Multi-Mull in the 1950s.
The current Simpson Multi-Mulls are the result of over 70 years of continuous research and practical field experience in sand preparation systems. Over 450 foundries around the world have relied on Simpson Multi-Mull to cost effectively and consistently prepare of their sand.

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