Over 50 Years of Experience Serving Foundries
Since the 1970s, foundry coatings, also known as refractory coatings, have represented Mazzon's core business.
These are water-based or alcohol-based liquid formulations applied to sand cores and moulds to prevent molten metal from penetrating or reacting with the moulding sand during casting.
The coatings contain powdered refractory materials that withstand high temperatures. These materials differ in terms of particle size distribution and refractoriness level and are selected according to the specific production requirements of each foundry.
Once applied to sand-resin moulds, they create a protective layer that separates the molten metal from the sand during casting, helping to achieve higher-quality castings and improved surface finish.
A Formulation Designed Down to the Finest Detail
In addition to the refractory component, each coating contains a specific system of suspending agents that determines its physical behavior by controlling viscosity, density, and thixotropy, while preventing the refractory fillers from settling at the bottom of the container.
The composition of the suspension system is designed according to the intended application method, which may include dipping, brushing, washing, or spraying.
The formulation also includes binders, which provide cohesion to the protective film; wetting agents, which ensure the proper dispersion of all components; de-aerating agents and anti-foaming agents, which prevent air formation and entrapment during use; as well as anti-fermentation agents, preservatives, stabilizers, pH regulators, flow-enhancing or thickening additives, colorants, and fragrances.
More Quality, Fewer Defects
Selecting the most suitable coating helps reduce or eliminate many surface defects, such as burn-on, metal penetration, veining, and gas-related defects.
A smoother and more uniform casting surface also reduces the risk of scrap and minimizes subsequent cleaning and finishing operations, resulting in significant savings in both time and costs.
Tailored Solutions for Every Foundry
MAZZON develops and manufactures coatings formulated in both alcohol-based and water-based versions, according to the specific production requirements of each foundry.
For every type of casting, moulding process, and application method, Mazzon identifies the most effective and high-performing solution, ensuring the best balance between performance and cost.
For this reason, the company's technical sales team works closely with foundries and their production departments on a daily basis, helping to identify the most suitable solution based on application requirements and the technical and metallurgical characteristics of each process.
Research & Development for Continuous Innovation
At the same time, the Research & Development laboratories work continuously to customize formulations according to customer requirements and develop new solutions, identifying alternative raw materials capable of ensuring high performance, consistent quality, and increasingly competitive costs.
Over the years, market evolution and the continuous fluctuation in the cost of certain refractory raw materials have encouraged both foundries and coating manufacturers to seek innovative components that can optimize the production process and progressively reduce overall costs without compromising product performance.
Consistent and Controlled Quality
Consistent quality is one of the fundamental principles of the company's operations.
Through rigorous controls on raw materials, production processes, and finished products, the company ensures long-term performance repeatability and the stability of the parameters that define each formulation.
Every parameter is carefully evaluated and optimized to ensure maximum application efficiency and the highest final casting quality.
Special High-Technology Applications
Alongside traditional coatings intended for No-Bake and Cold-Box processes, the company has developed over time a range of highly specialized products for the Automotive sector, for Full-Mould and Lost-Foam processes with polystyrene patterns, for the production of centrifugally cast pipes and cylinders in cast iron and steel, and for numerous other industrial applications requiring high standards of precision, reliability, and technological content.
Technology, expertise and experience at the service of casting quality.