CASE STUDY:
GRAHAM WHITE DSM3 REBUILD

EMI converted a roughly 50-year-old hydraulic machine to servo drives and installed a new combustion system. Downtime went away, and two minutes came off the cycle.

Graham White’s DSM3 Machines

Graham White runs DSM3 machines. The design dates back roughly 50 years and runs on hydraulics. DSM3s are uncommon, and Graham White has chosen to rebuild them with EMI. A fourth machine is at EMI and has been inspected.

Two Systems Set Uptime and Cycle Time

The rebuild targeted the hydraulic drive and the combustion system, the two systems that governed how long the machine ran between repairs and how fast it produced.

One Standard for Every EMI Rebuild

Every EMI rebuild runs through one documented procedure. Each job starts from a proven sequence instead of starting over, applied where it fits the machine:

• Complete Teardown: The machine comes down to component state. Reusable parts are high-pressure washed, ground free of foreign metals, primed, and painted.

• Cylinders and Valves: All cylinders are rebuilt or replaced, including barrels and rods when required. Solenoid valves are rebuilt or replaced as required.

• Electrical: All machine-mounted electrical is new, including conduit, sealtite, and wire, along with major components such as pressure switches and limit switches.

• Piping and Air Preparation: All piping is new, rigid and hose. Pressure regulators, filters, lubricators, and gauges are new and located for service.

• Controls: A new PLC control panel goes into a free-standing, sloped NEMA 12 enclosure.

• Inspection and Testing: Every machine goes through final inspection and thorough testing before it ships.

Servo Drives and a New Combustion System

The standard restores a machine. Upgrades move it forward. EMI updates and modifies equipment to fit current processes, and on the DSM3 that meant two changes. The hydraulic drive came out and servo drives went in. A new combustion system replaced the existing one.

Close to Double the Production

The servo conversion eliminated downtime and reduced maintenance. The new combustion system cut cycle time by two minutes, and production came close to double. Graham White has since sent a fourth machine to EMI.

The Same Work for Other Machines

The DSM3 is an uncommon machine. The servo conversion and combustion work applies to other foundry equipment, built on the same documented procedure. EMI remanufactures foundry equipment of all types, including machines from its own brands: CE Cast, Harrison, Herman, IMPACT, Osborn, SPO, and Sutter.

Talk with EMI about rebuilding the machines already on the floor.