Melt
Kohler Co. has five Inductotherm, 35-ton-capacity, coreless melting furnaces. There are three 45-ton-capacity, channel inductor holding furnaces. Their capacity affords greater process flexibility and results in highly consistent chemistries. Impurities and oxides are removed from the iron before it is transported to the holding furnaces. Overhead monorail transfer ladles deliver molten iron from the 35-ton electric melting furnaces to the 45-ton holding furnaces, making delivery timely and safe.

Core Making
Precision cores are produced on cold box and pep-set equipment. Core quality is maintained by testing, dimensional gauging, weighing and visual inspection. Only A-1 cores are accepted for production. After cores are produced, they are transported to the molding line where they are prepared for pouring.

Molding Center
The Osborn in-line molding machine produces 300 molds per hour and utilizes a conveyor-type pouring line. The line allows for the use of multiple pouring ladles and provides multiple core-setting stations. The Osborn flask size used in foundry production of gray and ductile iron is 28" x 34" with a 9" cope over a 9" drag.

Casting Finishing
A centralized cleaning and finishing facility ensures every casting is quickly and thoroughly processed, no matter what its size. Castings are finished on Wheelabrator machines which use grit or steel shot to mechanically clean castings, and then manually spot finished to obtain desired finishes.

Equipment: 28-cubic-foot Wheelabrator tumblast with skip bucket loader and Wheelabrator compartment spinblast with four 40-hp blasting wheels

To our customer’s advantage, Kohler arranges packaging and delivery on an individual customer basis. This ensures that you’ll get your casting packaged exactly the way you specify and delivered by your usual carrier.

Pattern Facility
A leading-edge, in-house pattern facility helps to maintain high-quality production standards as well as save time and money. Whether it’s downloading your CAD files to create tooling, running solidification software to troubleshoot before actual production or working with skilled craftsmen to build the patterns and core boxes, our staff will assist you with casting design, product improvement and cost savings to achieve the highest quality for your casting products.

The Kohler Engineering department is fully staffed and available to execute total design of foundry patterns, core boxes, fixtures, allied tooling and equipment required for production of sand cast products. Our pattern shop is capable of manufacturing and repairing a wide range of equipment. All pattern equipment is dimensionally verified before production castings are made. Pattern makers are capable of working with steel, aluminum, wood and urethane equipment.