Maintenance Tips For Older Molding Machines
Older molding machines deserve the same care and attention as any high-value tooling in a foundry. Some of these machines have been running for years, reliably pressing out mold after mold without a hiccup. But without steady upkeep, even the most reliable system can wear down. Machines that aren’t well-maintained tend to show signs of strain in ways that threaten both output and safety. Productivity dips, molds come out off-spec, and operators start spending time fixing instead of running.
Neglect often starts small—a few cycles missed on lubrication, a strange vibration ignored, or slight wear in part of the frame. But over time, those small issues start stacking up, causing machinery to break down when it’s needed most. Whether it’s a manual molding press or an automatic matchplate system, catching these risks early and following a consistent upkeep routine can help extend service life and save on costly downtime.
Visual Inspections Should Be Routine
Visual inspections are the easiest way to spot trouble before it spins out of control. It doesn’t require any deep technical skill or complex analysis. Just a trained eye, some patience, and a regular routine. Catching a cracked weld early or seeing a slow-forming leak around hydraulic hoses can be the difference between a brief stop or an extended shutdown. Machines like manual molding presses, dual station setups, or automatic matchplate systems benefit from this simple habit.
When you walk around the machine, focus on the areas listed below:
– Surface damage: Look for cracks in the frame or hairline fractures near load-bearing points
– Leaks: Check for fluid buildup around hydraulic connections, air lines, lubrication ports, or under gassing systems
– Loose fittings: Pay attention to bolts, clamps, or covers that might be vibrating loose over time
– Corrosion: Spot early rust around metal joints or electrical enclosures before it compromises performance
– Hose and wiring wear: Look out for frayed covers, bent fittings, or burnt connectors
Keeping a log of what you find helps a lot. That way, any change from one inspection to the next can point to a developing issue. A small mark that hasn’t grown is probably safe to monitor. But if it changes shape, leaks, or spreads between checks, it’s time to act. Set a schedule that fits your production rhythm—before every shift, once a week, or during changeovers—whatever keeps things under control.
Lubrication and Cleaning Go Hand-In-Hand
If your machine isn’t lubricated properly, moving parts start grinding instead of gliding. That turns into heat, wear, and slowdowns. Once that happens, you’ll start to see double-cycles, sticking patterns, and worse mold separation. Parts such as the ejection system on an automatic matchplate machine or the lifting mechanism on a Savelli automatic tight flask press depend on clean contact points and well-applied lubrication.
Use the correct oils and greases that pair with the machine’s specs. For older molding machines, this often means matching original manufacturer guidelines or talking to a service technician if the specs have changed over time. Avoid over-lubing. Extra grease attracts sand and resin dust, which can clog moving sections and form grit that wears down joints and sleeves.
Cleaning should follow close behind. Sand and resin aren’t shy about spreading. They collect in every open spot, corner, and gap unless they’re removed often. Cleaning helps keep blow plates, mold cavities, and box carriers working like they should. Wipe down accessible areas during regular changeovers, and plan deep-clean intervals monthly or quarterly based on how dirty your environment gets.
These two steps—lubrication and cleaning—should always be paired. Lubricate to prevent wear. Clean to keep that lubrication working the way it’s supposed to. Simple, consistent habits here keep larger problems from building up down the road.
Track Performance Metrics Over Time
If your older molding machine starts to fall behind the pace of production, performance metrics can help shine a light on where things are slipping. Don’t wait until mold quality drops or output slows to start asking questions. Data from the machine—how long a cycle takes, reliability between runs, changes in pattern fill or venting—can point to deeper issues that aren’t obvious during a walk-around inspection.
Start by recording cycle time benchmarks during normal operation. Once you’ve got that baseline, review any deviations. An increase in cycle time might signal binding clamping units, worn seals, or issues with the blow head on a dual station cold box system. Even slight timing shifts between ejection and mold fill can add up to delays over a full shift.
Here are some helpful reminders:
– Track cycle times during production and compare across shifts
– Review consistency in ejection and mold strip rates
– Measure mold quality for voids, short fills, or rough edges
– Use downtime logs to help identify repeat failures or stops
– Consider software-based monitoring tied to sensors for blow pressure, clamp force, and timing
Modern tooling like vertical-horizontal core systems or 3-in-1 setups may offer digital feedback features. Take advantage of these if your machines have the capability. And if they don’t, even basic manual records can help build a trend history. That kind of information comes in handy when planning maintenance or diagnosing underperformance. Over time, tracking these metrics gives you a clearer picture of machine wear without having to tear anything apart to check.
Know When It’s Time for a Pro
There’s only so far daily checks and logs can take you. At a certain point, old parts wear out, tolerances shift, and problems go beyond what you can handle in-house. That’s when pulling in a technician can help protect both production and uptime. Experienced service teams know where pressure imbalances develop, how much play is too much on guide rails, or why a swing arm isn’t indexing like it used to.
Emergency repairs often cost more and hurt schedules more than planned maintenance. If something starts creaking, leaking, or failing consistently, don’t wait for it to fully shut down. It usually works out better if a machine is offline for a day of professional adjustments instead of being out two weeks due to serious failure.
Here are a few situations where outside support makes sense:
– Continued air pressure inconsistencies when operating a QuickCore or 3-IN-1 unit
– Repeated mold stripping issues on a manual matchplate machine
– Hydraulic drift or temperature imbalances in the system
– Frame wear or guide damage that requires realignment or part replacement
– Software or sensor malfunctions in automated molding cores
Bringing in experts also helps when modifying machine performance or updating part runs. For example, switching a core box in a prototype or manual setup may require changes to blow pressure, cure timing, or pattern venting to get the right results. Working with someone who’s done it before can save hours of trial and error.
What It Takes to Keep Older Machines Running Strong
Keeping older molding systems reliable doesn’t require constant repairs—it’s more about steady, sensible care. That includes inspecting machines on a set schedule, cleaning and lubricating them correctly, and tracking performance over time. When problems stretch beyond everyday fixes, get professional help before issues turn into long stops or missed targets.
Machines that are over a decade old can still produce excellent work. They just need the right support to stay that way. Regular checks help spot damage before it spreads. Cleaning and lube routines reduce strain. Watching performance numbers tells you when things aren’t running the way they should. Together, these daily habits help keep cold box cores, matchplate systems, and other foundry tools working longer, with fewer surprises.
Taking maintenance seriously protects more than just the equipment. It supports the people running the machines, the quality of the casting output, and the flow of jobs through the foundry floor. Planning for downtime is always easier than scrambling when things break. Keeping that in mind sets up both your team and your machines for smoother days ahead.
Regular maintenance ensures your older equipment remains a valuable asset for years to come. If you’re ready to maximize efficiency and avoid unexpected downtimes, explore our molding machines. EMI is here to help you maintain a smooth and productive operation with expert advice and top-of-the-line solutions.
