New Castle Industries
Contact: Fred Scocchera
PO Box 7359
1399 Countyline Rd
New Castle, PA 16107
U.S.
Phone: 724-656-5600 / 800-8
Fax: 724-656-5620
Company Background
New Castle Industries, an Ampco-Pittsburgh company, is headquartered in New Castle, PA, and was formed in 1971. Through growth and acquisitions, New Castle currently consists of eight divisions and subsidiaries:
Feed Screws
Injection and Extrusion Screws
NCI Northeast
Regional Screw Manufacturing
NCI Southeast
Regional Screw Manufacturing
Tanner
Rolls for Sheet and Film
F.R. Gross
Rolls for Film, Converting, & Printing
Keystone
Rolls for Sheet and Film
Bimex
Bimetallic Barrels
Machinery
Custom Machines and Rebuilding
New Castle specializes in the design, engineering and manufacture of feed screws and barrels for injection molding and extrusion, and chill rolls for sheet, film, converting, printing, and other heat transfer plastic processes. Our focus has always been dedicated to innovative screw technology advancements and plastic process development and improvement.
New Castle holds numerous patents on specialty designs like our StratablendTM Mixing Screw that can be designed for both Injection and Extrusion applications. Our patented ContraBendTM Reverse Deflection Chill Roll is re-writing the book on wide, perfectly flat thin gauge sheet processing. F.R. Gross features the patented Equatherm® Spiral roll which is designed for maximum heat transfer and minimum fluid flow. Our Bimex subsidiary's SuperCarb® barrel is the hardest bimetallic barrel available today with tungsten carbide forlonger wear life.
New Castle realizes different companies have different needs. We offer complete engineering services to augment your engineering staff or to take full responsibility for many types of repair or retrofit projects you may have. Equipped with AutoCad and electronic data transfer, your projects leap ahead to meet your schedule and your performance expectations.
Customer service is at the basis for our success. That's why we have numerous regional sales offices staffed with Sales Engineers who can meet with you to review your projects on site. Backed by our large engineering staff, we can often recommend cost effective options for your consideration.
Thank you for visiting our site and we look forward to servicing your needs.
Also visit these sites: www.frgross.com and www.keystonerolls.com.
Extrusion Screws
Repair/Rebuild Services
Complete repair/remanufacturing/resurfacing services for extrusion applications.
Quality awareness, quick delivery, competitive pricing and hassle-free customer service are our priorities at New Castle Industries. Our computerized scheduling system ensures accurate delivery quotes at the time or order:
* We completely inspect your screw within 24 hours of arrival at our facility. Our inspection includes:
* OD wear
* Flight width
* Root/radius damage
* Bearing wear
* Spline/key condition
* Over torque condition
* An accurate estimate of repair is provided in writing and reviewed by phone prior to start of work.
* Since we are experts in screw design, we can often suggest improvements to help your screws perform better and last longer.
* Flight repairs are performed using our multi-step welding process utilizing plasma transferred arc welding with a complete quality control system. Our method ensures consistent hardness, minimizes "cracking" and eliminates bonding problems. All welds are full flight width for improved wear life.
Available welds:
* Colmonoy 56
* Colmonoy 83
* Stellite #1, #12, #6
* DuraFlight CX (hi-abrasion resistant)
* Root and radius repairs, as required, are made with compatible base metals or hardsurfacings for value added protection against future damage.
PRODUCTS
Extrusion
Screws (New)
Screws (Rebuild/Repair)
Stratablend
DuraFlight SR-2420
Extrusion Barrels
Injection Molding
Screws (New)
Screws (Rebuild/Repair)
Stratablend
SuperCarb
Injection Barrels
Chill Rolls
Chill Rolls (New)
Chill Rolls (Rebuild/Repair)
ContraBend
SERVICES
Engineering Services
Extrusion Screws
New & OEM Replacement
Complete engineering, manufacturing and design services for extruders.
New Castle Industries recognizes the quality issues associated with acquiring replacement screws for your process. That's why we're the largest manufacturer of screws and supply many original equipment manufacturers (OEM) everyday . We offer the following services:
* Complete engineering services and CAD drawings including reverse profiling for any single screw and many twin screw extruders.
* High quality standards ensure proper fit and performance at competitive prices. Plus, our post manufacturing inspection department checks every part to print for tolerances and finish prior to shipment.
* Standard base material construction is 4140 heat treated steel and options are available:
* 4340 heat treated steel
* Nitralloy 135M
* Hastelloy
* All grades of stainless steel
* Flight hardsurfacings are applied using our custom developed plasma transferred arc welding method and quality control system, ensuring consistent hardness while minimizing "cracking" and bonding problems. Available welds:
* Colmonoy 56
* Colmonoy 83
* Stellite #1, #12, #6
* DuraFlight CX (hi-abrasion resistant)
* We use no "substitutes" to guard against barrel compatibility issues.
* Full length coatings are available and offer additional protection to processors using fiberglass or talc reinforced resins.
* Weld encapsulation
* Praxair LW1 - N30
* Chrome plating
* Screw design services offer processors an opportunity to evaluate extruder performance and possibly improve output, melt quality or melt temperature for any resin applications commonly used today. A simple analysis enables New Castle to recommend the proper screw design to help meet your current requirements.
L/D Retrofits - Vented or Non-Vented
Any extruder can be modified to meet challenging process requirements. Extended (L/D) length screw/barrel combinations can help stabilize surging problems while often increasing output performance. Shortened (L/D) length screw/barrel combinations help reduce temperature sensitive resin resonance time and can be designed for reduced output. New Castle Industries offers single source engineering, manufacturing and design services for complete retrofit packages.
The retrofit includes:
* Proper design screw
* Barrel adjusted for L/D
* Heater bands (as required)
* Cover modifications (as required)
* Front barrel support modifications (as required)
Extrusion Screws
Repair/Rebuild Services
Complete repair/remanufacturing/resurfacing services for extrusion applications.
Quality awareness, quick delivery, competitive pricing and hassle-free customer service are our priorities at New Castle Industries. Our computerized scheduling system ensures accurate delivery quotes at the time or order:
* We completely inspect your screw within 24 hours of arrival at our facility. Our inspection includes:
* OD wear
* Flight width
* Root/radius damage
* Bearing wear
* Spline/key condition
* Over torque condition
* An accurate estimate of repair is provided in writing and reviewed by phone prior to start of work.
* Since we are experts in screw design, we can often suggest improvements to help your screws perform better and last longer.
* Flight repairs are performed using our multi-step welding process utilizing plasma transferred arc welding with a complete quality control system. Our method ensures consistent hardness, minimizes "cracking" and eliminates bonding problems. All welds are full flight width for improved wear life.
Available welds:
* Colmonoy 56
* Colmonoy 83
* Stellite #1, #12, #6
* DuraFlight CX (hi-abrasion resistant)
* Root and radius repairs, as required, are made with compatible base metals or hardsurfacings for value added protection against future damage.
Stratablend
for Compounding/Extrusion Applications
A proven, high performance "universal" compounding design screw for most resin blend applications.
Highly effective for glass or CaCo3 and talc related processing requirements, the Stratablend supplies the output with well dispersed reinforcements and improved physical properties. The Stratablend screw can be designed to maximize both distributive and/or dispersive types of mixing. This flexibility offers the following advantages:
* Creates little temperature rise for improved process control.
* Intensive compounding action with minimum glass fiber breakage.
* Improved output for greater production and profits.
* Self-cleaning action reduces purging time resulting in less downtime and lower costs.
* Reduces additive and color requirements.
* Improved homogeneity provides better physical properties and more usable product.
TYPICAL APPLICATIONS
* 10 - 40% fiberglass filled PP, Nylons or Styrenes.
* 10 - 40% talc filled PP, PE or Styrenes.
* 10 - 40% talc and/or glass filled PBT, BET or Nylons.
* All color concentrate applications.
* All engineering resin applications.
DuraFlight SR-2420
Screw/barrel combination for extrusion
Screw/barrel combinations that feature long wearing, high carbide concentrations -- designed for optimum wear surface compatibility.
The DuraFlight SR-2420 screw/barrel combination is perfectly matched to your processing requirement to offer maximum wear life, less downtime, and more throughput per maintenance dollar spent.
DuraFlight Screw
* Manufactured to your design or ours.
* Features premium, maximum wear resistant hard-surfacing options.
* Reduces screw repair requirements and the maintenance downtime.
* Our full-width CX-3 Alloy is one of the longest wearing hard surfacings available and is specially designed using high loadings of tungsten carbide particles in a strong durable nickel matrix for optimum compatibility with our SR-2420 barrel liners.
* Maximum compatibility with our SR-2420 barrel liner.
SR-2420 Barrel
* Features superior wear resistance for extrusion applications.
* Displays less segregation of carbides generally exhibited by high carbide bearing alloys.
* Features 55-60% blended carbide concentration.
* Offers optimum compatibility with our DuraFlight screw hardsurfacings.
Abrasive Wear Applications
* Compounders processing glass-filled materials.
* Talc-filled, CaCo3 filled or other filled materials.
* Products that require high TiO2 loadings.
Adhesive Wear Applications
* LLDPE & Metallocene blown film processors.
* HDPE film, sheet and blow molding.
* Scrap reclaim requirements
Bore Scope Alignment Services
* NewCastle offers bore scope alignment services for all screw/barrel packages we supply.
* Proper alignment is critical for maximum wear life of the screw and barrel.
Bimetallic Barrels for Extrusion
Our Bimex Bimetallic Barrel Division is a leader in supplying engineering and manufacturing services to OEMs and processors for over 30 years.
Extrusion processors have special needs when using screws and barrels. At New Castle, we match the right barrel liner to your process requirements.
AR-1000 Bimetallic Barrel
Our standard liner for all general purpose, unfilled noncorrosive processing.
QC-9100 Bimetallic Barrel
Our high-carbide liner for enhanced, unfilled resin processing applications.
SR-2420 Bimetallic Barrel
Our high-carbide liner for filled resin and other high wear processing applications.
CR-3680 Bimetallic Barrel
Our line of corrosive resistant liners for processing resins like RPVC and Fluoropolymers.
What is a Bimetallic Barrel?
A bimetallic barrel is a carbon steel cylinder that has a metallurgically bonded "super alloy" inner lining. These extremely hard alloys are formulated to withstand highly corrosive and/or abrasive effects of processing today's engineering resins at often elevated temperatures. Different alloys have various degrees of corrosive and wear resistant elements to ensure excellent performance compatibility.
How is a barrel made?
All of our barrels are produced by placing an alloy inside a carbon steel backing cylinder, sealing the ends and heating it at a temperature high enough to melt only the alloy inside. The hot barrel is then rotated at high speed, centrifugally coating the interior with the lining alloy. The molecules of the backing material actually interchange, creating an inseparable metallurgical bond. The bimetal cylinder is then finish honed and can be further machined or fabricated as needed.
Injection Screws
New & OEM Replacement
Complete engineering, manufacturing and design services for injection molders
New Castle Industries understands molders' concerns regarding replacement screws for all their presses; proper compression ratios, fit and end cap clearance are critical for consistent quality molded parts. We offer the following services:
* Complete engineering services, CAD drawings and reverse profiling for late model or imported machines.
* High quality standards ensure proper fit and performance at competitive prices. Plus, our post manufacturing inspection department checks every part to print for tolerances and finish prior to shipment.
* Standard base material construction is 4140 heat treated steel and options are available:
* 4340 heat treated hi-carbon
* Nitralloy 135M
* CPM tool steels
* All grades of stainless steel
* Flight hardsurfacings are applied using our custom developed plasma transferred arc welding method and quality control system, ensuring consistent hardness while minimizing "cracking" and bonding problems. Available welds:
* Colmonoy 56
* Colmonoy 83
* Stellite #1, #12, #6
* DuraFlight CX (hi-abrasion resistant)
* We use no "substitute" hard surfacings to guard against barrel compatibility issues.
* Full length coatings are available and offer additional protection to processors using fiberglass or talc reinforced resins.
* Weld encapsulation
* Praxair LW1 - N30
* Chrome plating
* Screw design services offer molders a complete single source supplier that can help when processing engineering resins on general purposes screws. We analyze the application and recommend the proper screw design to provide:
* Consistent shot size
* Better mixing of color or dissimilar resin blends
* Improved screw recovery cycles
* Better temperature control to help eliminate "splay"
Up/Downsize Conversions - Vented or Non-Vented
Any injection press that is either too small or too big to accommodate the intended shot size can be converted to an ideal capacity. New Castle offers you single source engineering, manufacturing and design services for complete retrofit package.
The retrofit includes:
* Proper design screw
* Barrel adjusted for L/D and diameter
* Heater bands
* End cap
* Check valve
* Nozzle
* Base extensions (as required)
Injection Screws Screws
Repair/Rebuild Services
Complete repair/remanufacturing/resurfacing services for injection molding applications.
Quality awareness, quick delivery, competitive pricing and hassle-free customer service are our priorities at New Castle Industries.
* We completely inspect your screw within 24 hours of arrival at our facility. Our inspection includes:
* OD wear
* Flight width
* Root/radius damage
* Female Thread
* Spline/key condition
* Over torque condition
* An accurate estimate of repair is provided in writing and reviewed by phone prior to start of work.
* Flight repairs are performed using our multi-step welding process utilizing plasma transferred arc welding with a complete quality control system. Our method ensures consistent hardness, minimizes "cracking" and eliminates bonding problems. All welds are full flight width for improved wear life. Available welds:
* Colmonoy 56
* Colmonoy 83
* Stellite #1, #12, #6
* DuraFlight CX (hi-abrasion resistant)
* Root and radius repairs, as required, are made with compatible base metals or hardsurfacings for value added protection against future damage.
* Full length coatings offer additional protection to molders processing fiberglass or talc reinforced resins. Available coatings:
* Nitriding
* Praxair LW1 - N30
* Weld encapsulation
* Chrome or nickel plating
Injection Screws Screws
Repair/Rebuild Services
Complete repair/remanufacturing/resurfacing services for injection molding applications.
Quality awareness, quick delivery, competitive pricing and hassle-free customer service are our priorities at New Castle Industries.
* We completely inspect your screw within 24 hours of arrival at our facility. Our inspection includes:
* OD wear
* Flight width
* Root/radius damage
* Female Thread
* Spline/key condition
* Over torque condition
* An accurate estimate of repair is provided in writing and reviewed by phone prior to start of work.
* Flight repairs are performed using our multi-step welding process utilizing plasma transferred arc welding with a complete quality control system. Our method ensures consistent hardness, minimizes "cracking" and eliminates bonding problems. All welds are full flight width for improved wear life. Available welds:
* Colmonoy 56
* Colmonoy 83
* Stellite #1, #12, #6
* DuraFlight CX (hi-abrasion resistant)
* Root and radius repairs, as required, are made with compatible base metals or hardsurfacings for value added protection against future damage.
* Full length coatings offer additional protection to molders processing fiberglass or talc reinforced resins. Available coatings:
* Nitriding
* Praxair LW1 - N30
* Weld encapsulation
* Chrome or nickel plating
DuraShell Chill Rolls
for sheet - film - paper coating - heat transfer applications
Complete in-house manufacturing and extensive processing experience have made New Castle Industries the leader in supplying heat transfer rolls for processors and OEM's for the last 25+ years.
IN-HOUSE CAPABILITIES
* Hard chrome plating
* Vertical stress relief
* Large diameter honing
* Heat transfer analysis
* Complete roll manufacturing and assembly
* Dynamic balancing
DESIGN
The key to roll performance starts with a coordinated design analysis of your particular requirements. Every roll we design is analyzed for heat transfer, mechanical strength and materials selection resulting in maximum performance.
MANUFACTURING
Over 25 years of manufacturing experience has made us the leader in supplying heat transfer rolls for processors and OEM's alike. We quality control the complete machining, grinding, boring, honing and welding of all our rolls up to 48" diameter and 300" lengths, at .0005" TIR standard.
FINISHING
We offer optical mirror "superfinish" to coarse matte finishes applied over hard chrome plating.
Additional industry finishes are available:
* Water retention
* Flash plating over matte
* Pocket release
* 30 - 50% gloss
Durashell Chill Roll - ideal for plastic sheet lines are manufactured from low carbon steel tubing pre-machined and hard surface overlayed with 420 stainless steel (48 - 52 Rc). The resulting residual roll has been field tested and proven superior to carburized and flame hardered shells for minimizing worm tracking failures and reconditioning costs.
Chill Rolls
Repair/Refinishing Services
Complete repair/remanufacturing services of chill rolls for sheet, film, paper coating and heat transfer applications.
* Regular maintenance and/or modified finish requirements are our specialty. Combined with total in-house chrome plating and finishing equipment, New Castle Industries offers committed customer service and accurate delivery quotations with every request. Our capabilities include:
* 48" diameter and 300' lengths
* Acid flush and flow testing
* Journal and body repairs
* Repolish existing chrome
* For finishing, we offer optical mirror "superfinish" to coarse matte applied after chrome plating
* Plus specialty industry finishes:
* Water retention
* Flash plating over matte
* Pocket release
* 30 - 50% gloss
* Our precision finishing facility enables us to provide .0005 TIR on every order regardless of size or weight.
ContraBendTM Chill Rolls
Reverse Deflecting Chill Rolls
A retrofit chill roll design that utilizes the effect of roll deflection in any diameter/face length/sheet gauge combinations resulting in optimum flat sheet.
EXCLUSIVE NEW CHILL ROLL DESIGN
New Castle Industries has developed a reverse deflection chill roll that has proven extremely effective when processing thin sheet or coextrusions. The ContraBend chill roll design minimizes the effect of roll deflection with any roll diameter/face length.
The roll design utilizes basic internal mechanical bending principals and requires no additional hardware, changes in existing processing parameter or control devices. There is no external visual difference between a conventional chill roll or the ContraBend. Simply replace existing chill rolls with a matched set, and you'll see the benefits:
* The elimination of convex-shaped sheet due to roll deflection for improved thermoforming - resulting in scrap reduction.
* Reduced materials costs by eliminating the convex shape thereby maintaining "low-limit" gauge tolerances with less polymer.
* Permit thin cap layers in coextruded products without distortion.
HOW IT WORKS:
The physical appearances of both the conventional chill roll and the ContraBend are identical, but internally are quite different. In the ContraBend roll, the shell is not connected to the journals, thus allowing for the shell to bend one way and the journal the other when pressure is applied. The rolls will bend proportionately to the amount of pressure applied depending on application so that the roll gap is always perfectly parallel.
The ContraBend roll simply conforms to the shape of the second roll, eliminating the convex sheet attributed to conventional chill roll designs.
FINISHING
We offer optical mirror "superfinish" to coarse matte finishes applied over hard chrome plating.
Additional industry finishes are available:
* Water retention
* Flash plating over matte
* Pocket release
* 30 - 50% gloss
Durashell Chill Roll - ideal for plastic sheet lines are manufactured from low carbon steel tubing pre-machined and hard surface overlayed with 420 stainless steel (48 - 52 Rc). The resulting residual roll has been field tested and proven superior to carburized and flame hardered shells for minimizing worm tracking failures and reconditioning costs.
Design Services
One of New Castle's specialties is providing our customers with enhanced performance screw designs. Whether injection or extrusion, New Castle can custom design screws for your machines and materials to meet the specifications and performance you need.
Machine Rebuilding
For over 20 years, our Machinery Division has focused on our customer's performance modifications necessary to update their older existing equipment and at a fraction of the cost of new machinery. Complete rebuilds or field retrofit packages are available for most US-built machines.
EXTRUDERS
L/D Retrofits-Vented or Non-Vented
Any extruder can be modified to meet challenging process requirements. Whether extending (L/D) for improved performance, gear box rebuilding, or a complete cooling system for an extruder overhaul, we're well equipped for your custom requirements.
We recently completed this sheet line rebuild - the next best thing to buying new equipment!
INJECTION MOLDING MACHINES
Up/Downsize Conversions-Vented or Non-Vented
Any injection molding machine that is either too small or too big to accommodate the intended shot size can be converted to an ideal capacity. We offer you single-source engineering, manufacturing and design services for complete retrofit packages.
We also offer custom machinery manufacturing services.
Bore Scope Alignment
After the time and money you spend to retrofit your screws and barrels, don't rely on a "local" service to ensure proper alignment. More screw/barrel wear and gear box damage is caused by mis-alignment than most other reasons under normal use. Our field technicians inspect every aspect of the alignment including the critical start-up checks with full reports.
Lab Services
You've got a new resin to run, but improper screw designs to test the material. No problem, New Castle has a complete lab facility with screw inventory available for you try it out on. We will even supply a complete report and screw recommendation with each resin trial.
