production

1. Fusion

The melting equipment is consisted by:

- 3 propane gas furnaces, with a capacity of 180 kg respectively for tin, aluminum and brass; - 1 electric resistance furnace with capacity of 200Kg crucible for tin.

Note that each furnace is always dedicated to melt the same alloy, avoiding the contamination of the bath. There is only one alloy of tin , aluminum and brass.

The hourly capacity of the melting furnace is about 80 Kg. The sprues and remains - they are fused part - are separated and placed in small wooden or cardboard, which contributes to housekeeping the sector.

Daily, there is a fusion in the morning and in the evening. The monthly production is about 2 tons of tins and two tons of aluminum. Annual statement: the order of 50 tons of parts, divided in roughly equal parts by the two leagues.

2. Molding

The whole molding is manual, using a wedge and silver pressers. In order to reduce the space inherent to this process and, simultaneously, increase productivity, it is expected to use pneumatic pushers. The transport of molds to the places of leakage and its closure, is done without any auxiliary equipment.

There are two molding areas: one for tins and one for aluminum.

Are also used, the two sand molding processes:

- Current Procedures: it is used for small series or pieces. Using the loose mold - which appears as a metal plate with the shape and thickness of the cast to get - it are made up two successively molds, the bottom and the top, as usual.

- Procedure for series considered significant: this sheet-molding process is a seldom used procedure, since the series are generally reduced.

- For opening the down gate, with this upper molding already pressed down, uses a thin-walled tube of a collection of tubes with several different diameters, which with the pressure on the molding opens a hole in it and the result is a billet of sand inside the tube from where it is subsequently shaken.

- For the manufacture of very small pieces is also used the centrifuged mold. For this purpose, there are three vertical axis centrifuges. The molds, of silicone rubber, are made at Decampos.

3. Leakage

The manual transport of liquid metal from the ovens to the leak places, is made ​​with small piped spoons, managed by a single worker.

In the leak place there is a gas burner, from a household barrel type, which takes the material to the pouring temperature. Althought it isn't used no weights or clamps to compensate the thrust of the liquid metal and prevent the lifting of the molds while the liquid metal, during this time the moulder - or other worker - exert some force on the upper molding, pressing it with two rods.

4. Tin

In this sector, exclusive of tins, is resumed to the welding of components, castings or sheet, which form the piece, using some small gas torches. Also it covers some holes and other defects with a solder.

In some cases - the most common - on the containers which the bottom are in live angled with themself walls, the link of both is made by welding, because, in molding, sharp edges of the sand would breaks (the experience of the manufacters dixit).

Then, its time for the sharpening of the welded parts. This area - physically separated from the other by a glass wall - 14 people are working, a very meticulous work. It is also the most populous sector. At one end there are some simple machine tools, including a drilling machine and a cutting disc.

5. Sanding

Adjoining the tin sector, constituting the next stage of the process, which is the place of sanding the tins, with two double millstones grinders. In total, there are 10 workers.

6. Cleaning

After sanding there is a cleaning operation carried out on a vibrating machine. The cleaning agent is kind of steel ball "wash".

After polishing the pieces went to a washing facility with trichlorethylene to remove the soap.

7. Finishing and
Final Control

In this sector, following the cleaning of parts and is common to pewter and aluminum, is carried out manually cleaning parts with chalk and gypsum application of the skate, skating operation is called.

8. Turnery and
Warehouse Moulds

The company has three lathes used for repushing and other operations.

The molds are on wooden shelves. This sector will be benefited from an appropriate location of the molds. These, made in the house by the main charge worker, are made of tin, aluminum and copper.

9.Environment

Outwardly, nothing betrays that beyond a stark wall is an industrial activity and even less, a foundry.

Five independent units suction ensure the maintenance of a satisfactory environment. These units are distributed in the following areas:

Casting, tin, sanding and polishing machines, lathes, individual aspiration for aluminum. The aspiration is carried out by means of grills placed along the main pipes disposed near the ceiling and through flexible tubing to the existing nozzles, for this purpose, the machines.

10. Quality Control

As a fundamental requirement of the company's, the quality control is ensured throughout the entire product manufacturing, and also covers the manufacturing process itself and the raw material.

An especialized worker, permanently at the factory, ensures maximum accuracy in finishing process to each piece that goes out of Joao Vieira de Campos, Ltd.

As for the raw material, this process is certified by the EPU - European Pewter Union. The association brings together the most renowned producers of Europe, requires that all parts have constituted at least 97% tin. All our pieces are minted with the warranty seal of EPU.

As you can see in the picture, the stamp of EPU identifies the country and certified company. In this case, the first digit corresponds to Portugal and the rest to João Vieira de Campos, Ltd.