Jencast expanding capacity to increase capabilities, improve production at casting facility.

As a means to increase its production capabilities, Jencast Inc. (Jensen International Inc.), Coffeyville, Kan., is in the process of augmenting its green sand iron casting facility in South Coffeyville, Okla., a decision spanning back to 1997.

In 2003, the firm completed the installation of a 44 x 56-in. 22/22-in. (111.75 x 142.24-cm 55.88/55.88-cm) cope and drag molding line to offer customers services lost after Jencast's nobake molding operations ceased in 1995. Despite the new line, Jencast is limited to three production shifts in which it can operate only one of its two molding lines at the same time due to the capacity of other departments. However, the firm is investing in equipment to have the capability to run both molding lines simultaneously, which will give Jencast the capacity to triple production.

"As growth continues, the new molding line will be transformed into a fully automated indexing mold line (during the next 3-4 years)," said Eric Jensen, Jencast's president. "Currently we are in the process of reconfiguring a punchout unit and have a pattern shuttle on order."

As customer requirements grow, the firm also plans to transform its induction melters from single-phase units to medium frequency to increase melt capacity by 125%. In the cleaning room, the firm is installing a spinner-hanger blaster with plans of robotic grinding units, and expects to reconfigure its core room and add production core blowers.

Further, Jencast looks to build a 36,000-sq.-ft. machining shop, moving the operation from its current Coffeyville, Kan., facility to reduce transportation costs and place jobbing capabilities in one location.

"With the new machine shop, we will have the capability to machine the casting envelope of parts produced on the new line and be able to offer all the current services for all of its products," Jensen said.