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A true leader in its industry, Rochester Metal Products has been producing gray and ductile iron castings since 1937. Located in Rochester, Indiana, RMP ships more than 50,000 tons of iron castings each year. Our state-of-the-art facility houses more than 200,000 square feet of manufacturing space and is divided up into two separate plants; Our automated Disamatic plant produces ductile castings from Disa vertical molding machines at high speed production rates and our Hunter plant produces gray iron castings on horizontal Hunter molding machines. Our core making department has the ability to produce complex, geometric cores both utilizing Cold-Box and No-Bake molding methods. RMP features its own in-house pattern shop, grinding and finishing department, as well as a fully equipped inspection and quality lab equipped with the latest Auto-CAD, EDI, 3D Modeling and Solidification software. Our plant is currently staffed with 3 full time degreed metallurgists and our ownership routinely is reinvesting in the company, as it is an absolute necessity in this competitive industry. Rochester offers casting design assistance for new products from original concept to prototyping and final production.
Profile
- Established in 1937
- IS0 9001:2008 Certified
- Over 200,000 Sq feet of manufacturing
- Operates 3 shifts approximately 150 employees
- Industries served (but not limited to); Agriculture, Air Compressor, Automotive, Valve and Pump, Construction, Marine, Lawn and Garden, Gear,
- Plumbing and Heating, Medical/Dental, Municipalities and more
- Alloys Cast-
- Gray Iron- Class 25, Class 30, Class 35
- Ductile Iron- 65/45/12 As Cast, 80/55/06 As Cast, 60/40/18 Heat Treated
- Weights
- Gray Iron- # 1 to 50 lbs
- Ductile Iron- # 1 to 40 lbs
- Volumes
- Hunter Plant- 70+ Net Tons of Good Castings/Day
- Disamatic Plant- 166+ Net Tons of Good Castings/Day
Facility
Molding
Hunter Plant
- Hunter Molding Machines- horizontal parting line
Size Range
| Flask Size |
Min WT. |
Max WT. |
Max Length |
Max Height |
| 14" x 19" |
.75 lb |
20 lb |
16" |
6" |
| 20" x 24" |
1 lb |
50 lb |
21" |
9" |
Core Production
- We offer a wide range of core design and production capabilities in both cold box and shell processes
Disa Plant
- Disamatic Molding Machines- Vertical parting lines
Size Range
| Min WT. |
Max WT. |
Max Length |
Max Height |
| .75 lb |
30 lb |
19" |
10" |
Core Production
- Rochester Metal has vast experience in producing simple to intricate and complex coring systems
- Offer a wide range of core design and production capabilities in both cold box and shell processes
Melting and Cooling
General Melting Equipment
- 2 Brown Boveri 11 ton/hour coreless melting furnaces (35 ton holding capacity each)
- 3 Ajax 1500kw Jet Flow 3.0 ton/hour Electric Channel Induction Furnaces (35 ton holding capacity per furnace)
- 4 10 ton cranes with digital weight display for charging
- 2 Venetta gas-fired pre-heaters
- 2 Quick Labs for iron analysis and melt analysis on melt deck
- 3 - 8,000 lb capacity ladle cars with monorail distribution system
Adequate cooling time is critical to iron production. Rochester Metal features some of the longest cooling lines in the industry; ensuring parts are structurally and dimensionally stable.
Disa Plant
- Our Electric Melters and Vertiplex holding furnace maintain chemical and temperature control prior to ductile treatment
Grades of Ductile Iron Poured
| Ductile Iron Grades |
Hardness Range |
Min.
Tensile
Strength |
Min.
Yield
Strength |
Percent
Elongation |
| 60-40-18* |
170 Max |
60,000PSI |
40,000PSI |
18 |
| 65-45-12 |
156-217 |
65,000PSI |
45,000PSI |
12 |
| 80-55-06 |
187-255 |
80,000PSI |
55,000PSI |
6 |
| 100-70-03 |
241-302 |
100,000PSI |
70,000PSI |
3 |
Hunter Plant
- Electric channel induction melting furnaces along with real-time spectrographic chemical analysis provide the highest quality gray iron for our customers.
Grades of Gray Iron Poured
| Gray Iron Grades |
Hardness Range |
Min.
Tensile
Strength |
| Class 25 |
170-229 |
25,000PSI |
| Class 30 |
187-241 |
30,000PSI |
| Class 35 |
207-255 |
35,000PSI |
Grinding and Machining
- Conventional processing and automatic trim ties used to remove gates and parting lines required
- Paint, heat treat and machining processes can be added to provide complete casting
Engineering and Quality
- ISO 9001:2008, QS9000 certified
- ISO 14001- Environmental Standard
- Engineering services available to form "Partnerships" in development of new or existing products. Design changes can be considered to reduce casting cost.
- 5 full time staffed metallurgists
- We offer CAD and EDI capabilities along with Solid Modeling and Solidification Simulation. These technologies aid us in designing proper tooling to meet customer needs
- Computers are networked our facility for real-time statistical analysis of our iron chemistries, sand characteristics, Brinell hardness, and tensile properties. Nodularity tests are executed on the last mold of each ladle poured.
- Lab Highlights;
- Ultrasonic Inspection
- Complete Sand Laboratory
- FARO Gold Arm® portable CMM
- ATAS- Adaptive Thermal Analysis System
- Jarrel-Ash Spectrometer with computerized controls for instant analysis of 17 elements
Contact us to learn more. To request a quote please send inquiries to
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Typical Parts produced today:
Axle caps, Control Arm Frames, Bearing Housings, Bearing Caps, Suspension Brackets, Gear Boxes, Wheel Hubs, Gear Pump Housings, Gear Blanks, Water Pumps, Compressor Housings, Manifolds, Gas Valves, Pulleys, Clamps, Fittings
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