Binder savings and better castings: MinSand in core and mould production
In foundry operations, core and mould materials play a critical role in determining casting quality, production efficiency and overall cost control. As margins tighten and sustainability expectations increase, foundries are looking more closely at how raw material choices influence binder demand, process stability and defect rates.
One area receiving renewed attention is the sand itself. While traditional silica sand remains widely used, alternative materials such as MinSand are increasingly being specified to support both technical performance and operational efficiency in core and mould production.
Why binder efficiency matters
Binders represent a significant proportion of consumable costs in foundry processes. Whether using organic or inorganic systems, excessive binder demand can increase material spend, extend curing times and introduce challenges during shake-out and reclamation.
From a casting quality perspective, higher binder content can also contribute to defects such as gas porosity, veining and surface blemishes. Reducing binder usage without compromising strength or dimensional accuracy is therefore a key objective for many foundries.
Achieving this balance depends not only on binder chemistry, but also on the physical and chemical properties of the sand used in the system.
Understanding MinSand
MinSand is a by-product material derived from the mineral processing of high-quality anorthosite rock. Unlike natural silica sand, MinSand has a consistent mineralogical composition and a more uniform particle shape, offering predictable behaviour in foundry applications.
These characteristics allow MinSand to perform reliably across a range of core and moulding processes, including cold box, no-bake and inorganic binder systems.
Reducing binder demand through sand optimisation
One of the key advantages of MinSand lies in its surface characteristics. Its lower specific surface area compared to angular silica sands allows binders to coat particles more efficiently. As a result, equivalent or improved core and mould strength can often be achieved with reduced binder addition.
This delivers several practical benefits:
- Lower binder consumption, helping reduce raw material costs
- Improved gas permeability, supporting cleaner casting surfaces
- Reduced gas generation during pouring, lowering the risk of porosity
- More consistent curing behaviour across production batches
For foundries producing high-integrity castings, these improvements can translate directly into higher yield and reduced scrap rates.
Improving casting quality and consistency
Casting defects are rarely caused by a single factor, but sand performance plays a central role. Variability in sand grading, shape or chemistry can introduce inconsistency into core strength, collapse behaviour and thermal stability.
MinSand offers a stable alternative, with tightly controlled particle size distribution and minimal variability between deliveries. This consistency supports repeatable core and mould performance, helping foundries maintain tighter process control.
In addition, MinSand’s mineral composition provides good resistance to thermal shock, reducing the risk of veining and cracking in demanding casting environments. Improved surface finish and dimensional accuracy are common outcomes when sand behaviour is more predictable.
Supporting reclamation and environmental goals
Environmental responsibility is now an integral consideration in foundry operations, driven by both regulatory pressure and customer expectations. Reducing binder usage contributes directly to lower emissions and energy demand during casting and sand reclamation.
MinSand can also support improved reclamation efficiency. Lower binder levels and cleaner burn-out behaviour can make mechanical and thermal reclamation more effective, extending sand life and reducing waste disposal volumes.
As a by-product material, MinSand also contributes to more efficient use of natural resources, aligning with circular economy principles without requiring changes to existing production infrastructure.
Compatibility with modern binder systems
As foundries explore new binder technologies, particularly inorganic systems designed to reduce emissions and odour, sand compatibility becomes increasingly important. MinSand has demonstrated strong performance with a wide range of binder chemistries, offering flexibility as processes evolve.
Its predictable behaviour helps foundries transition between binder systems while maintaining casting quality and production stability.
A practical step forward for core and mould production
Moving to MinSand does not require wholesale changes to equipment or process design. Instead, it offers a practical route to incremental improvement – reducing binder consumption, improving casting quality and supporting sustainability objectives through material optimisation.
For foundries seeking to enhance competitiveness while managing cost and environmental performance, MinSand represents a proven alternative to traditional silica sand in core and mould production.
Backed by LKAB Minerals’ technical expertise and secure supply, MinSand helps foundries focus on what matters most: consistent production, better castings and more efficient use of resources. Follow LKAB Minerals on LinkedIn today for the latest product updates, case studies, and industry insights!
