Projects

HamiltonJet steers heavy-duty foundry operations with Dyno Conveyors

HamiltonJet is a long-standing name in New Zealand manufacturing. Founded by Bill Hamilton at Irishman Creek and operating from their Christchurch site since the 1940s, the company controls the entire production process for its world-renowned water jets - from raw aluminium ingot through to final assembly. In the foundry, where sand moulds are formed and cast, the team ran into a very practical problem. These moulds can weigh up to half a tonne, and the way they were being handled was putting strain on people and equipment alike. Add in the dust and grit of the foundry environment, and the existing setup was being pushed well beyond its limits. Looking for a solution that could handle the weight and survive the conditions, HamiltonJet turned to long-time partner Dyno Conveyors.

THE CHALLENGE

Manoeuvring massive loads around tight corners

In the foundry, sand and resin are packed into patterns and left to harden, forming the moulds used for molten aluminium. Once filled, these patterns are extremely heavy – typically between 400kg and 500kg. Moving them in a straight line was challenging enough, but the real issues showed up at the corners.

“It was very hard to push them around corners,” says Jacob Sikma from the HamiltonJet team. “They twisted quite a lot. They weren’t aligned and straight.”

Correcting that twisting took real physical effort and created ongoing ergonomic concerns. On top of that, the equipment struggled to cope with different pattern sizes and weights. What the team needed was a system that took the strain out of handling and kept everything tracking straight, every time.

The Solution

Heavy-duty gravity rollers with precision cornering

With more than a decade of experience working together, Jacob knew Dyno could deliver. We spent time on site understanding the realities of the foundry – particularly the extreme weights involved and the abrasive nature of sand and dust. From there, we designed a heavy-duty gravity roller system built for smooth movement and long-term reliability.

  • Tapered rollers for perfect alignment

To stop the twisting at corners, tapered rollers were installed through the turning sections. Unlike straight rollers, the tapered design naturally guides heavy loads through bends while keeping them aligned. “With some levelling and adjustment to suit all sizes and weights of patterns… they go around corners quite nicely and they are ergonomically perfect to push patterns forward,” Jacob explains.

  • Bearings built for the grit

Foundries are tough on moving parts, with fine sand and dust working their way into everything. The rollers were fitted with high-quality, sealed bearings designed to keep contaminants out. The result has been impressive. “It’s been here now nearly two years… and I don’t think we have replaced one single roller yet,” says Jacob.

  • Separate lines with pneumatic integration

The process required two separate lines – one carrying moulds and another delivering cores – to come together. Dyno designed a simple pneumatic transfer that allows cores to cross over and merge smoothly with the main line, without manual handling or delays.

  • Adjustable, sturdy framing

With constant heavy loads, the frames needed to be strong and adaptable. Heavy-duty adjustable legs were used, allowing levels to be fine-tuned over time as the system beds in and takes ongoing wear.

The Result

Effortless handling and zero downtime

The difference on the foundry floor was immediate. What had once been hard, physical work became smooth and controlled. Friction was reduced to the point where even 500kg patterns can now be handled by one person.

“It’s very easy to push them,” says Jacob. “One person can push them forward and stop them where they need to be.”

Just as importantly, the system has stood up to the environment. After nearly two years of daily use in a sand-filled foundry, there hasn’t been a single roller replacement. It’s a clear example of what happens when equipment is designed specifically for the job.

Here’s what’s changed:

  • Ergonomic strain eliminated
    One person can easily manoeuvre 500kg patterns without physical struggle.

  • Cornering issues solved
    Tapered rollers keep heavy loads aligned through turns.

  • Durability
    No roller replacements after two years in a harsh, dusty environment.

  • Improved workflow
    Pneumatic transfers allow production lines to merge smoothly.

  • Fit-for-purpose design
    Strong, adjustable frames handle constant heavy loads with ease.

Customer Testimonial

Why would you go anywhere else?

“The Dyno roller conveyors are great. They can hold the load. The frames are very sturdy because it’s been here now nearly two years, and Dyno came up with a great solution. Why would you go anywhere else?”

Jacob Sikma

HamiltonJet

Products

Dyno products used in this project

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