This page contains a Flash digital edition of a book.
When Regal Cast was established, the company installed an Argon Oxygen Decarburization (AOD) vessel.


PRL, but an early decision paved the way for a strong casting operation. When Regal Cast was established,


the company installed an Argon Oxygen Decarburization (AOD) ves- sel. Te AOD refines metal, and PRL believes that Regal Cast is the smallest metalcaster in the world that has one of these vessels. Tat nugget aside, the AOD gives Regal Cast distinct advantages. Te AOD cleans and optimizes the metal, allowing larger castings to be poured. Regal Cast can melt up to 18,200 lbs. with the vessel at its largest capacity. “The largest capacity vessel we


have now is a 7-metric ton vessel. That has grown over the years. We have several 5-ton vessels also,” said Greg Raudenbush, director of tech- nical operations, Regal Cast. “The advantage of the AOD is being able to refine your material and be able to re-use your returns, clean those up, utilize those again, and to build


20 | MODERN CASTING April 2017


your bath to the size that you need in order to pour larger castings.” Recently, Regal Cast added a new


PLC server to the AOD system. What that does is help the operator of the AOD better understand how to control gases and make metal addi- tions based on chemistries after the lab analysis, and assists with controlling slag chemistries. Regal Cast’s slags are calcium oxide, aluminum oxide and magnesium oxide, which is intentional to build a slag layer over the top of the molten metal. “It just helps the operator control those things better,” Raudenbush said of the PLC.


Independent But Together Regal Cast is just one part of


what PRL does. But just because it pours metal does not mean it stays away from the rest of the business. Interactions are frequent. “We have good people. Without


them we would not be where we are today,” Raudenbush said. “Te way I look at things is I like to break a com- plex process down into simple steps, and doing those very well. Everything else takes care of itself.” Raudenbush makes it sound easy,


and maybe it is for PRL. Tat ease, however, would not be possible if not for communication. Workers from each facility meet


every week, and meetings about spe- cific customers are common. Te com- munication lines are never closed, and they run from one facility to the next. “It is complicated,” said Chris-


topher Hess, the plant manager for the LTC machine shop in Cornwall, which is steps from the corporate office. “We keep the communication lines open and bring things up as soon as we see an issue, and just to make sure everybody’s on the same page we circulate reports. Every facility does a weekly report that gets circulated


Courtesy of PRL Inc.


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44  |  Page 45  |  Page 46  |  Page 47  |  Page 48  |  Page 49  |  Page 50  |  Page 51  |  Page 52  |  Page 53  |  Page 54  |  Page 55  |  Page 56  |  Page 57  |  Page 58  |  Page 59  |  Page 60