As Romi Fundição, a strategic business unit of Indústrias Romi SA, one of Brazil’s most established industrial manufacturers, continues to evolve its positioning in the foundry sector, the business set a clear and ambitious objective. The challenge: to become the most modern foundry in Brazil and mark a new chapter in the company’s foundry history.

To achieve this, Romi required a moulding solution capable of delivering:

· Superior and consistent mould dimensional quality.

· Reduced scrap rates, and therefore lower material and energy losses.

· Higher production efficiency, with minimal human intervention.

· Flexibility for frequent model changes, enabling shorter batches and higher product variety.

· Production cost transparency, with real-time cost control per mould and per cast part.

OMEGA SINTO PROVIDED THE SOLUTION

Omega Sinto Foundry Machinery Ltd delivered a complete technological upgrade, implementing a fully integrated moulding line, from sand storage to shakeout.

At the core of the project is a modern, automated moulding system designed to provide:

full line integration. Omega Sinto provided a complete solution covering the entire moulding process:

· Sand storage and handling.

· Mould preparation and moulding.

· Automated mould closing.

· Transfer through the line.

· Shakeout.

This end-to-end approach ensures consistent performance, reliable flow and a unified system designed to meet Romi’s production goals.

HIGH AUTOMATION WITH AUTOCLOSER TECHNOLOGY

The line features the Omega Sinto Autocloser system, which automatically closes moulds, eliminating manual mould closing and significantly reducing operator dependency.

This brings Romi:

· Faster moulding cycles.

· Minimal human intervention.

· Improved repeatability and process stability.

· Higher consistency across shifts.

QUALITY CONSISTENCY AND SCRAP REDUCTION

A key expectation from Romi is achieving superior dimensional accuracy and consistency in every mould. This offers them control over quality. Omega Sinto’s moulding line was designed specifically to support:

· Reduced mould variation.

· Stable and repeatable process conditions.

· Lower scrap rates.

· Measurable improvements in material and energy efficiency.

With fewer rejects, Romi anticipates not only quality improvements, but also real operational savings through reduced waste.

FLEXIBILITY FOR SMALLER BATCHES AND HIGHER VARIETY

Modern foundry markets increasingly demand shorter runs, greater variety and faster changeovers.

Romi required a system capable of adapting quickly without sacrificing quality or cycle time. Omega Sinto’s solution supports:

· Great flexibility for model changes.

· Increased agility for diverse market needs.

· Strong performance in both high volume and mixed production environments.

DIGITAL CONTROL AND COST OPTIMISATION WITH IRIS TECHNOLOGY

Beyond moulding automation, Romi also expects major performance gains through Omega Sinto’s control systems, including IRIS technology for pattern recognition.

Using IRIS, the benefits for the client are guaranteed to:

· Monitor and control production parameters.

· Optimise cycle performance.

· Track production costs per mould.

· Improve cost control per cast part.

· Make data driven decisions on productivity and efficiency.

This transforms the moulding line from ‘equipment’ into a strategic production platform, supporting long term competitiveness.

Romi Fundição is a strategic business unit of Indústrias Romi SA, one of Brazil’s most established industrial manufacturers, founded in 1930. Romi Fundição specialises in producing grey and nodular cast iron parts, supplying both raw and machined components to demanding industries including:

· Machine tools (Romi’s own product line).

· Capital goods.

· Automotive.

· Agricultural and construction machinery.

· Power generation (oil & gas).

· Railroad.

With a casting capacity of approximately 50,000 tons/year (greensand and no-bake), Romi produces components ranging from 10kg up to 35-40 tons, including large scale parts for wind turbine applications.


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