FOUNDRY CASTING NEWS

Saudi Aramco Signs to Set Up High-End Forging & Casting Manufacturing Facility

Saudi Aramco has signed a Memorandum of Understanding (MoU) with GE (NYSE: GE) and Cividale SpA of Italy to build the Middle East and North Africa’s first-of-its-kind high-end forging & casting manufacturing facility that will serve the region’s maritime and energy industries.

Marking a joint investment of over US$400 million (SAR1.5 billion), the new facility, to be located in Ras Al-Khair under the Royal Commission of Jubail and Yanbu industrial area, aims to establish a high-value supply chain that boosts exports and economic competitiveness. Set to be operational in 2020, the plant will create 2,000 quality jobs in the Kingdom and catalyze the growth of Saudi small and medium enterprises (SMEs).

The MoU follows a preliminary partnership between Saudi Aramco and Cividale, a leading European producer in the steel and cast iron sector, to conduct feasibility studies for forging and casting manufacturing services in the Kingdom. GE has come on board to extend its expertise and investment in developing the world-class manufacturing plant through a joint venture between the three entities.

The Forging & Casting Manufacturing Facility complements plans by Saudi Aramco to develop several industrial projects in the Kingdom including a maritime project focused on building, maintenance, repair and overhaul (MRO) of offshore platforms, jack-ups, offshore service vessels and commercial tankers.

Saudi Aramco is also working with its partners to develop an onshore rig manufacturing facility for providing new build and MRO services to onshore rigs and systems; an engine manufacturing project for the manufacturing, maintenance and repair of diesel engines, manufacturing and repair of marine pumps; and an Energy Industrial City to accelerate manufacturing industries in the oil and gas sector.

The Forging & Casting Manufacturing Facility will serve all these projects in addition to providing the best-in-class services and technologies to downstream & other industries across the region and global markets. It will also support the ongoing emphasis of the government, under Saudi Vision 2030, to develop the mining sector of the Kingdom by creating a domestic source-market for various raw materials & supplies that go into the production line.

Abdallah I. Al-Saadan, Senior Vice President, Finance, Strategy & Development, Saudi Aramco, said: “The MoU reflects our ambition to create a robust supply chain that builds positive synergies in the oil and gas manufacturing sector. This builds on our deep commitment to support the goals of Saudi Vision 2030 to promote economic and industrial diversification in the Kingdom and boost localized manufacturing.”

Rami Qasem, President & CEO, GE Oil & Gas, Middle East, North Africa & Turkey said: “For the Forging & Casting Manufacturing Facility, we will leverage our already strong expertise in ‘Made in Saudi’ manufacturing. Together with our partners, we will actively engage Saudi SMEs to support the plant’s operations, and train & hire Saudi professionals, adding further value to the economy. By building a domestic forging and casting production unit, Saudi and regional customers can achieve greater operational efficiencies in product procurement, repair and service support.”

Antonio Valduga, President of Cividale, added: “The feasibility assessment study underlines the strong potential for a world-class manufacturing facility for forging and casting services in the Kingdom. Developing a full-fledged facility through the joint partnership will position Saudi Arabia as a technology and services hub for specialized equipment and services.”

The collaboration is a strong example of the public-private partnerships that the government fosters under Saudi Vision 2030 to develop local manufacturing capabilities that add significant value to the economy.

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Magna Announces New Aluminum Casting Facility in the UK

Magna International Inc. today announced it will build a new world-class aluminum casting facility in Telford, United Kingdom, to support Jaguar Land Rover, the UK’s leading vehicle manufacturer.

The new facility is expected to be approximately 225,000 square feet and will create up to 295 jobs at full capacity. Working with the UK Trade & Investment and the Automotive Investment Organization, along with financial support from the UK Government’s Regional Growth Fund, helped to secure this project. Construction is expected to start in the autumn of 2016.

Once production begins in 2018, the facility will use Magna’s innovative high-pressure vacuum die casting process to produce a number of advanced lightweight aluminum castings– a key building block in the next generation all-aluminum and multi-material vehicle architectures.  By using these types of castings, Magna helps automakers deliver maximum strength and stiffness and minimum weight, ultimately achieving better fuel economy, safety and handling.

“We are excited to work closely with Jaguar Land Rover in the development of this project which will bring the most advanced structural casting technologies to the UK,” said John Farrell, President of Cosma International, an operating unit of Magna International.   “As lightweighting continues to be a key technology driver, we are uniquely positioned to help automakers achieve optimal weight savings throughout the vehicle architecture.”

Magna, through its Cosma International operating unit, is one of the world’s premier suppliers providing a comprehensive range of body, chassis and engineering solutions to automakers around the world.

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Schuler Acquires Leading Die Manufacturer AWEBA

Schuler AG, the market leader in forming equipment, is to take over the die construction specialist AWEBA and thus greatly expand its activities in this business field. Based in Aue, Germany, the AWEBA Group is one of the world’s leading full-service providers of dies and fixtures. Under the terms of the purchase agreement, Schuler will acquire a 100 percent stake in AWEBA Werkzeugbau GmbH Aue.

The transaction is still subject to the approval of the relevant anti-trust authorities. AWEBA Werkzeugbau GmbH was previously held by private and institutional investors. The parties have agreed not to disclose any details about the purchase agreement.

AWEBA was founded in 1882 as “Bernhard Hiltmann Spezialfabrik für Schnitt und Stanzwerkzeug”. The company today supplies international customers in the automotive and electrical industries, as well as machine and plant manufacturers. The product portfolio includes forming, cutting, hydroforming, and die-casting dies, as well as fixtures and a comprehensive range of services.
In fiscal year 2015, the AWEBA Group generated sales revenue of around € 60 million.

Schuler CEO Stefan Klebert commented: “We are delighted to add a successfully managed company like AWEBA to our Group. With its high level of expertise in research and development and excellent engineering know-how, the company is a perfect fit for Schuler. The acquisition is part of our growth strategy. AWEBA complements our product portfolio in forming technology in line with market requirements and will expand and strengthen our existing activities in die construction.”

The AWEBA Group employs around 600 people, including almost 200 highly skilled engineers and toolmakers. The company owns 40 valuable patents in the field of die manufacturing.

AWEBA CEO Udo Binder stated: “Becoming a member of the Schuler Group opens up tremendous opportunities for the further expansion of AWEBA. Schuler’s global market standing will enable us to quickly grow our international presence and enhance our profile as a global system supplier. This gives AWEBA growth opportunities which would not have been achievable without Schuler.”

The AWEBA takeover is Schuler’s second major acquisition in the last twelve months. Last year, the company acquired a majority stake in the Chinese press manufacturer Yadon with annual sales of around € 110 million.

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Hitachi Metals Automotive Components to Be Division of Waupaca Foundry

Waupaca Foundry Inc., Waupaca, Wisconsin, announced it will merge with Hitachi Metals Automotive Components USA LLC (HMAC). The merger is part of a larger reorganization within Hitachi Metals Foundry America designed to position the integrated organization for growth and meet customer demand.

According to a news release, Waupaca Foundry will assume the assets and liabilities of HMAC. Both companies are currently subsidiaries of Hitachi Metals Foundry America (HMFA). After the merger, HMAC will become a division of Waupaca Foundry, but will continue to operate under the HMAC name.

Subject to customary conditions, the merger is expected to be complete on April 1.

Daily operations at Waupaca will not be impacted, and the merger is part of the firms’ strategic alignment.

“The merger with HMAC allows us to further integrate castings and value added services for our customers in diverse markets,” said Gary Gigante, CEO, Waupaca Foundry. “We are committed to being the world’s leading casting solutions provider, and this is a critical step in achieving that goal.”

In 2014, Hitachi Metals Ltd. purchased Waupaca Foundry from KPS Capital Partners LP, a New York-based private equity firm.

Waupaca Foundry produces gray iron, ductile iron and austempered ductile iron castings and employs more than 3,900 people at six manufacturing facilities, including three in Waupaca and others in Marinette, Wisconsin; Tell City, Indiana; and Etowah, Tennessee.

HMAC produces cast, machined and assembled ductile iron suspension and exhaust components for global automotive OEMs. It currently operates a machine and assembly plant in Effingham, Illinois, as well as a ductile iron casting facility in Lawrenceville, Pennsylvania.

The company employs 485 people across all locations.

“This reorganization further unites Hitachi Metals’ product design engineering expertise and materials development with Waupaca Foundry’s manufacturing excellence,” said Eddie Nakano, president and CEO, HMFA. “The merger will unite an experienced leadership team that is focused on delivering the most innovative products and technology to a growing base of global customers.”

HMAC CEO Mike Nikolai said the merger is a response to increased customer demand.

“Centralizing machine and assembly operations allows us to be more flexible in meeting the evolving demands of our customers,” Nikolai said. “We’ve already increased overall operational capacity and are positioning our organizations for long-term, sustainable growth.”

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