The global automotive casting industry is undergoing a rapid transformation driven by automation and precision manufacturing. As automakers demand higher consistency, lighter materials, and lower costs, traditional molding systems are struggling to keep pace.
Leading flaskless molding machine factory China are now providing cutting-edge Horizontal sand shooting solution technologies that help automotive component suppliers achieve unprecedented efficiency and casting precision.
1. Case Study: From Brake Caliper Bottleneck to Productivity Breakthrough
A major Eastern European brake caliper supplier for international OEM brands faced persistent challenges in its sand molding stage:
Uneven sand compaction causing a scrap rate between 3%–5%
Unstable cycle times and inconsistent output
Heavy reliance on manual operations, increasing labor costs and training demands
After several failed attempts to optimize their process, the company turned to Quanzhou Juneng Machinery Co., Ltd., a subsidiary of Fujian Shengda Machinery Group — a leading China foundry equipment manufacturer with deep expertise in sand injection and flaskless molding systems.
Juneng provided a comprehensive foundry automation solution, not just a machine. Their fully automated horizontal flaskless molding line featuring advanced Horizontal sand shooting solution completely transformed production.
Within three months, results spoke for themselves:
| Metric | Before | After (Juneng flaskless molding line) | Improvement |
|---|---|---|---|
| Molding cycle | 52 sec/mold | 34 sec/mold | +35% |
| Scrap rate | 4.8% | 1.3% | -72% |
| Operators per shift | 8 | 5 | -38% |
| Pattern changeover | 15 min | 5 min | -67% |
| Annual output | 120,000 molds | 168,000 molds | +40% |
“This flaskless molding line from China didn’t just change our capacity — it changed our competitiveness.”
— Production Director, European Automotive Foundry
2. Industry Pain Points: The Bottlenecks of Traditional Molding
According to Statista, the global automotive casting market is expected to reach USD 78 billion by 2027, with Chinese technology becoming a major growth driver.
However, traditional vertical or semi-automatic molding machines face three key issues:
| Pain Point | Description | Impact |
|---|---|---|
| Uneven compaction | Sand density variation up to ±8% | Dimensional inaccuracies, porosity defects |
| Unstable cycle times | Heavy dependence on manual operation | Limits continuous production |
| High cost & energy use | 20–30% higher per-mold energy | Raises per-part cost |
To compete globally, automotive suppliers need a smarter, faster solution — one that flaskless molding machine factory China are now leading.
3. The Solution: Intelligent Flaskless Molding from China
1. Horizontal Sand Shooting — The Precision Breakthrough
The heart of Juneng’s technology lies in its Horizontal sand shooting solution.
Unlike vertical systems, this dual-pressure horizontal injection design delivers:
Shooting velocity up to 4.2 m/s with sand density tolerance within ±2%
Stable compaction for complex automotive castings such as brake calipers, hubs, and steering knuckles
Reduced turbulence and uniform sand hardness
With intelligent closed-loop pressure monitoring, every mold achieves identical quality.
Customers report a 12% reduction in machining time thanks to tighter dimensional precision.
2. Modular Automation — The Path to a “Lights-Out” Foundry
As a leading China foundry equipment manufacturer, Juneng integrates full-process automation — not just the machine itself.
In this case, the company supplied a molding machine for automotive parts along with a complete line interface upgrade:
Automatic sand feeding and recycling system — 18% sand savings
Intelligent line pacing control — synchronized operation across stations
MES-ready data collection — live monitoring of production and quality metrics
Remote maintenance system — online diagnostics and updates
This end-to-end integration defines a complete foundry automation solution, enabling continuous, unmanned production.
3. Smart Control and Energy Efficiency
Juneng’s proprietary PLC architecture and HMI interface feature automatic diagnostics and self-calibration.
The energy management algorithm dynamically adjusts power consumption based on real-time cycle data, cutting overall energy usage by 22%.
This next-generation molding machine for automotive parts delivers both top-tier precision and sustainable energy performance — meeting global standards for green manufacturing.
4. Technical Comparison and Performance Metrics
| Item | Traditional Molder | Juneng Flaskless Horizontal System | Advantage |
|---|---|---|---|
| Molding Type | Vertical, with flask | Horizontal, flaskless | Higher accuracy |
| Sand Injection | Single-direction | Dual horizontal injection | More uniform density |
| Pattern Size Range | 400×350 mm | Up to 900×700 mm (customizable) | Flexible |
| Cycle Time | 45–60 sec/mold | 30–35 sec/mold | +30% faster |
| Hardness Variation | ±8% | ±2% | Superior consistency |
| Energy Use | High | -25% | Energy efficient |
| Labor Need | 8–10 operators | 4–6 operators | Automation ready |
With these performance advantages, flaskless molding machine factory China have reached international standards — offering both reliability and cost efficiency that global foundries value.
5. Global Trend: China’s Acceleration Toward Smart Manufacturing
According to the Global Foundry Market Report 2025:
The foundry equipment market is growing at a 7.1% CAGR
Chinese equipment exports are rising at 11.3% annually
Automotive parts account for 42% of total molding machine demand
This shift marks a turning point — China foundry equipment manufacturer are no longer just suppliers, but full-scale foundry automation solution providers offering smart, integrated systems for international factories.
6. Customer ROI and Global Feedback
Based on Juneng’s database, 78% of customers recover their investment within 12 months.
| Customer Type | Application | ROI | Satisfaction (1–5) |
|---|---|---|---|
| Brake Caliper Foundry | Mass production | 11 months | ★★★★★ |
| Agricultural Parts | Mixed line | 14 months | ★★★★☆ |
| Construction Machinery | High-strength castings | 12 months | ★★★★★ |
The numbers prove one thing — flaskless molding machine factory China deliver tangible, measurable value.
7. Frequently Asked Questions (FAQ)
Q1: Is Juneng’s system suitable for all automotive parts?
A: Yes. Our molding machine for automotive parts supports brake calipers, engine blocks, suspension brackets, and more. Parameters can be customized per mold geometry.
Q2: Is the Horizontal sand shooting solution complex to maintain?
A: No. The quick-release design allows daily maintenance in under 30 minutes.
Q3: Can it integrate with existing foundry lines?
A: Absolutely. Our foundry automation solution includes full interface design and data connectivity to MES and ERP systems.
Q4: Are the machines certified for export?
A: Yes, all systems are CE and ISO9001 certified with full English operation support.
Q5: Do you offer training and installation?
A: As a professional flaskless molding machine factory China, we provide both on-site and remote installation support, along with bilingual manuals and video training.
8. Conclusion: China’s Power in the Efficiency Revolution
From R&D to global service, Quanzhou Juneng Machinery Co., Ltd. is redefining foundry efficiency standards with advanced engineering and automation.
In the competitive automotive casting industry, success is no longer about cheap labor — it’s about smart production and consistent output.
With Horizontal sand shooting solution, system-level foundry automation solution, and specialized molding machine for automotive parts, China’s manufacturers are leading the next era of intelligent foundry technology.
9. Call to Action: Make Smart Molding Your Competitive Edge
This case is only the beginning.
Real value lies in measurable success for every customer.
If your foundry is struggling with efficiency, cost control, or quality consistency,
download our White Paper on Flaskless Molding Lines for Automotive Castings,
or schedule a virtual factory tour today to see how a China foundry equipment manufacturer like Juneng can help you redefine productivity.
Quanzhou Juneng Machinery Co., Ltd.
— Smart Molding, Smarter Manufacturing.
