Progressive Foundry Enhances Sand Consistency with the Simpson Multi-Cooler®
Progressive Foundry, an iron foundry focused on quality and continuous improvement, was looking for ways to reduce scrap and improve overall casting consistency.
Their goal: gain tighter control over sand cooling and moisture to deliver stable, repeatable sand properties across their molding lines.
Why Simpson
When evaluating options, Progressive identified the Simpson Multi-Cooler® as the only system capable of both measuring and controlling output moisture. Unlike other sand coolers that add water based on incoming sand temperature, the Multi-Cooler continuously monitors and adjusts moisture levels to maintain a consistent output—ensuring uniform sand quality.
Confidence in Simpson’s equipment also played a role.
“We already had a 22G Simpson Multi-Mull® that was built well, so we trusted the Multi-Cooler would be a quality product as well,” the Josh Magill, Plant Engineer shared.
Implementation
Installation was smooth, with much of the system arriving preassembled. Once operational, the impact was immediate.
“The consistency of the sand leaving the muller is much better than expected. The Multi-Cooler does 100% of what Simpson promises it will do.” — Josh Magill
Results & Impact
With the Multi-Cooler in place, Progressive achieved a new level of control and consistency in their green sand system:
- Compactability held within ±2 points 90% of the time
- Compactability held within ±3 points 95–98% of the time
- 7% reduction in bond usage relative to iron poured
Even when running beyond the rated capacity of their 22G Multi-Mull, the system continues to deliver stable, high-quality sand with reduced mulling time.
More Than Cooling
For Progressive Foundry, the Multi-Cooler has proven to be more than a cooling system—it’s a process control tool.
“It returns consistent, tempered sand back to the silo that can be easily mulled to a quality green sand. There’s nothing comparable to it in the market.” — Josh Magill
