Skip to main content
GullySystem
Manufacturing · Software for sand casting foundries

Keep the sand tests, melt chemistry and rejection causes behind every sand casting.

A sand foundry makes tonnes of castings from sand that changes by the hour. The sand casting foundry software keeps the sand test, the melt analysis and the pour next to the casting that came out. Rejections are counted by cause, pattern and shift.

Share your requirements
At a glance

Sand casting turns on small variables. Moisture and compactability of the green sand, pouring temperature, core strength and inoculation all move a rejection rate up or down, sometimes within a single shift on one moulding line. They are measured on paper at the sand lab, the furnace and the moulding line, and rarely compared.

Software for sand casting foundries brings those numbers into one record per pattern and per heat. Planners see moulds made, poured and shaken out against the day’s plan, with every box that missed its pour listed by pattern and reason. Quality sees rejections by defect. The first records mirror your own patterns, sand lab tests and furnace heats, and nothing is assumed about how the foundry already runs.

How the work runs today

The foundry runs on patterns, flasks and core boxes for grey iron or ductile iron parts such as manhole covers, brake drums, pump housings and machine beds. The sand lab tests moisture, compactability and clay content on each shift and adjusts the mix. Fast work. Core shop staff make cores in shell or cold box processes and stack them for the moulding line.

Moulders close the cope and drag on a hand line or an automatic machine. The melt shop tests the charge in an induction furnace, treats the metal with magnesium for ductile grades and pours. After shakeout the castings go to shot blasting and fettling. Spectro and tensile reports for the heat go out with the delivery. Buyers expect them.

Where it breaks

What goes wrong for sand casting foundries without a proper system.

Sand readings stay in the lab

The sand lab jots moisture, compactability and clay figures on paper. When defects spike, nobody lines those readings up against the moulds made in the same hour.

Scrap is counted by the heap

Rejected castings go into one bin. The reason, whether sand drop, gas hole or mis-run, and the pattern behind it, is guessed by whoever sorts the pile.

Pattern wear goes unnoticed

Wooden and metal patterns lose their edges after thousands of moulds. By the time dimensions drift, the cause is traced through memory.

Core stock is miscounted

Cores are made in batches, left to cure and stacked beside the line. The line stops when the right core is not there. Nobody knows where it went, who took it or whether more are curing in the other bay.

Tonnage drives the price and the delay

Quotes are priced per kilo, but fettling, grinding and rejection add hours that the weight does not show. A job can look profitable until the final bill is checked against the hours the fettling shop really spent on it. Then it does not.

What the software does

What we would build for sand casting foundries.

Named the way your team already talks about the work. We start with whichever part the audit shows is costing you most.

Pattern and core box register

Hold every pattern, core box and flask size by customer, with mould count and the date of its last repair.

Sand lab log

Record moisture, compactability, clay content and sand temperature for each shift, then link those readings to the moulds made in that window, so a bad hour of sand can be found afterwards.

Core shop stock

Count cores made, cured and issued by pattern, so the moulding line is never waiting on a missing core.

Melt and pour log

Capture the charge, the furnace, the magnesium treatment, the spectro reading and the pouring temperature for every heat, and tie each heat to the exact moulds that were poured from it.

Shakeout, fettling and rejections

Count castings coming out of shakeout and record every rejection by defect, pattern, shift and cause. A recurring sand drop or mis-run is then traced to one pattern instead of blamed on the line.

Test reports

Compile chemistry, tensile and hardness results for each heat into the report a buyer expects.

Quoting by weight and process

Price a casting from weight, metal grade, core use and fettling hours, so the quote carries the grinding and chipping that a plain price per kilo leaves out of the job.

Before you talk to a supplier

A requirements checklist for sand casting foundries.

What to cover, which reports to ask for and what to put to every vendor, ready to print or save as a PDF.

Open the checklist
Ready product

A product already built for sand casting foundries.

It is adapted to how your business works before it goes live, and anything your trade needs that it lacks is added then.

Sand Casting Foundry Management Software

Patterns, core boxes, clay and moisture tests, core making, moulding, heats, rejections by defect, fettling and dispatch for sand casting foundries.

See the product
Solutions inside

The business modules sand casting foundries use most.

Each one is also available on its own, or inside a system built for you.

Services

The services behind it.

Business Process Automation

Approvals, reminders, follow-ups and reports that run on their own instead of on someone remembering.

Learn more

ERP, CRM and Business Software Implementation

One record of stock, orders, customers and accounts, set up so your team opens it every day.

Learn more

Data Engineering and Business Intelligence

Dashboards that answer the owner’s Monday questions without anyone building an Excel sheet first.

Learn more
How it works

How the work runs from Bengaluru for your city.

  1. 1

    The audit, by call

    A screen-share and a look at the sheets, accounting reports and WhatsApp groups your team uses. No travel needed.

  2. 2

    A written proposal

    Scope, what we build first and the cost, agreed in writing before anything starts.

  3. 3

    Build in short rounds

    Working screens shared every few weeks. Your team tests them from your own office.

  4. 4

    Go-live, in person when it helps

    For data migration and training we can come to your city. Travel is agreed in advance.

  5. 5

    Support online

    Fixes, changes and hosting handled remotely by the same team that built it.

Our work

Software we have built and run.

We only name clients whose work is published. These are systems our team designed, built and supports.

All case studies
Pet care and veterinary services

PetSeva: matching owners to the right vet, at any hour

A two-sided veterinary platform where vets are searchable by specialisation and bookable outside clinic hours. It now carries more than 2,000 veterinary doctors.

Read the case study Paying guest accommodation

SAM Atithi Pavathi: bed-level occupancy as the source of truth

PG management software where allocation, rates and invoices are derived from bed-level occupancy and not maintained in parallel spreadsheets.

Read the case study School transport services

SAM Tours: school transport on a single ledger

Registration, fee collection, routing and finance write to the same records, closing the gap between journeys run and fees collected.

Read the case study
Common questions

Questions sand casting foundries ask before they call.

Can sand readings be linked to defects?

Yes. Each reading is time stamped, and defect counts are tied to the same shift and pattern. The foundry team decides what to compare.

Does it cover both grey and ductile iron?

It can. Grades, treatment steps and the tests each grade needs are set up with your metallurgist.

Is it right for a jobbing foundry with many small patterns?

Yes. Pattern and core box registers matter most when dozens of part numbers recur through the year.

Can rejections be entered on the shop floor?

Yes. Supervisors key rejections on a phone or desk terminal as the shift closes, choosing the defect from the foundry’s own list.

What happens after I share my requirements?

An engineer reads what you send and replies within one business day. We then look at the software, spreadsheets and WhatsApp groups your business runs on today and write down what works, what slows your team down and what is missing. A demo login, a screen-share or a few screenshots are enough. You get a short written summary ordered by priority, with no obligation to hire us afterwards.

How much will the software cost?

We don’t publish a price, because it depends on what the system has to do. That first review settles the scope, and the cost goes into a written proposal before any work starts.

Related

Related industries.

Category

Part of a wider group.

Talk to us

Tell us how your business runs today.

A few lines on your spreadsheets, software and WhatsApp groups is enough. We reply the same working day.

  • No obligation
  • A reply within one business day
  • Your details stay private

Start with your requirements

Seven short steps that tell us what you need. An engineer reads them before getting in touch.

Share your requirements