Case Study Sand Casting Solves Corrosion and Reduces Cost

Overview

A manufacturer of food processing systems approached MetalTek to address a corrosion-related performance issue. The customer required a durable, high-quality solution from a trusted
U.S.-based supplier that met performance expectations while remaining cost-competitive.

Challenge

The customer’s design relied on weldments, which created corrosion concerns in certain areas of its food-processing equipment. While it recognized the value of a single-piece component without welds to improve durability and overall service life, it lacked experience with metal castings, particularly in material selection, manufacturability, and long-term performance.

Solution

The customer evaluated both a hog-out from solid material and a metal casting. MetalTek’s Carondelet Division developed a single-piece sand casting, applying design-for-manufacturability expertise to address corrosion concerns while remaining both practical to manufacture and cost-effective.

Carondelet supported the proposal through onsite engagement and in-person reviews, including a scaled 3D model of the part. This approach clearly communicated the solution, enabled early visualization of the final component, and differentiated MetalTek from competing suppliers.

Result

The customer selected Carondelet to produce a single-piece sand casting to replace the welded design. The resulting stainless steel component eliminated weld seams, improving corrosion resistance and long-term durability. The sand casting provided a lower-cost alternative to a hog-out by minimizing machining requirements while meeting performance expectations. Sourcing from Carondelet in Missouri also aligned with the customer’s preference for a U.S. supplier, improving supply chain reliability.

Contact MetalTek’s Carondelet Division to discuss sand casting solutions for demanding applications.