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Green Sand Molding.

Two Lines. Built for Volume.

High-production green sand casting with independent, redundant lines — built to keep your program running without interruption.

Excal operates two independent high-production green sand molding and pouring lines, each capable of producing castings across multiple alloys in a single shift. With two fully redundant lines, your production doesn’t stop when one is dedicated to another program — giving you reliable throughput and scheduling flexibility.

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Why Two Independent Lines Matter

Redundancy That Keeps Your Program Moving

A single molding line is a single point of failure. Excal’s two independent green sand lines eliminate that risk.

High-Volume Production

Both lines are configured for high-production throughput — supporting steady, long-term supply programs without schedule interruption.

Multi-Alloy Capability Per Shift

Each line can run multiple alloys in a single shift, giving us the flexibility to run your program alongside others without compromising quality or timing.

True Line Redundancy

Each line is fully independent — so maintenance, tooling changes, or a dedicated program on one line never delays yours.

Our Process — Green Sand Molding

From Pattern to Poured Casting

1

Tooling Setup


Your pattern is mounted and the line is configured for your alloy, pour weight, and mold dimensions.

2

Sand Preparation & Molding

Green sand is tested daily — in-house and verified at an outside source — and prepared to controlled specification. Molds are produced at high throughput on our automated lines.

3

Core Setting & Closing

Cores are set and molds are closed and ready for the pour — each inspected before metal is introduced.

4

Pouring & Shakeout

Metal is poured, cooled, and shaken out for cleaning, inspection, and further processing.

FAQ — Green Sand Molding

Your Questions, Our Answers

Our green sand lines handle castings from 1 to 75 lbs. in brass and bronze alloys — covering the full range of our standard production capability.

Yes. Each line is capable of producing castings in multiple alloys per shift, with alloy spot-check verification using our in-house spectrometer

Sand is tested daily to ensure consistent molding conditions. This is a core part of our ISO 9001:2015 quality system and helps prevent surface defects and dimensional variation between runs.

Lead time depends on tooling status and program volume. Contact our team with your drawing and requirements and we’ll give you a straightforward timeline.

Ready to Start Your Green Sand Casting Program?

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