John Winter

FOUNDRY PRODUCTS

www.johnwinter.co.uk
Our Company

Welcome
Inside, youll find details of our increasing product range which has kept us at the forefront of todays foundry industry.
To keep pace with the shift in location of foundry work, we now export our products to 40 countries across the globe and also
manufacture in the USA to supply the North and Central American market.
Our ongoing development of sand additives for cores, moulds and inorganic binders has enabled us to enter new markets with
problem solving products alongside our regular consumables.
With our expanding product portfolio, and outstanding commitment to providing technical solutions and on-going support, I see
only an exciting and indeed a rewarding future ahead.

Dale Lister - Managing Director

Our History
When John Winter & Co Ltd was founded in the early 1960s, our core business was supplying foundries with their consumable and
material requirements.
Over the years, our site in Halifax, West Yorkshire, has been completely re-developed and now provides modern storage facilities
and office accommodation. With a strong team of dedicated staff, we are strategically located to offer next day delivery to most
parts of the UK.
Through an established network of agents and distribution channels we also serve clients across Europe, Asia-Pacific, North America,
the Middle East and South African foundry markets. Today John Winter is well positioned as we continue to grow and develop our
influence and reputation in these overseas markets.
Although our traditions are firmly rooted in manufacturing, supplying consumables and providing technical solutions to the long-
established UK foundry business, we have strong commercial interests in other areas.
In 2006 we began the supply of consumables to pattern shops and model makers. This has allowed us to offer a relationship between
the pattern maker, foundry and consumable supply chain.
Over the years, our supply of plaster into the dental laboratory industry has developed and our product range expanded. We now
have nationwide coverage in the supply of dental laboratory consumables and laboratory furniture.
We have a number of established distribution arrangements with national and multi-national companies covering the supply of dextrin,
starches, resins and hardeners across a wide range of end users and industrial concerns.
As a mark of our commitment to service and maintenance of quality levels we operate the Lloyds Register Quality Assurance to
meet ISO 9001:2008 throughout our organisation.
John Winter is proud to have served foundries across the world for over half a century and we are determined to continue the high
service levels and product excellence for which we are renowned.

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 Contents

02 Our Company 15 Mould & Core Coatings

04 Geopol 16 Core Repair & Mould Sealant

05 Alphaset 17 Adhesives

06 Sodium Silicate Sand Binders 18 Sleeves

07 Sand Binders 19 Metal Filtration

08 Sand 20 Refractory Products

09 Oil Bonded Sand 21 Slagcure K

10 SC#2 - Green Sand Conditioner 22-23 Fluxes

11 AF#2M & AF#2MG - Anti-Veining Additives 24 Die Coatings

12 Sand Additives 25 Essential Extras

13 Parting Fluid 875 26 Our Customers

14 Release Agents 27 Warehouse

Call us for further enquiries or immediate phone orders on +44 (0)1422 364 213 03
Geopol - Reclaimable Inorganic Binder in Foundries

GEOPOL - Reclaimable Inorganic Binder

Key benefits in inorganic binder technology:
The ever growing environmental issues of fumes, odour, and waste
disposal have focused increased attention on the need to develop a Virtually no odour on mixing
process to reduce the environmental impact of casting production. Very low fume levels during pouring and shakeout
Geopol inorganic binder system, designed to produce moulds and
cores, is a proven sand binder, cured by adding a liquid hardener.
Minimal environmental impact (no VOC's)
Can be reclaimed up to 90%
The process differs from traditional sodium silicate in the way the
bond is formed. Geopol forms an amorphous inorganic polymer
Improved flowability of sand
exhibiting higher strengths at lower addition levels compared to the Improved surface finish
sodium silicate process which forms a colloidal silica gel. Improved sand compaction
One of the main benefits of the Geopol process, compared to other Improved breakdown over conventional silicates
inorganic processes, is the ability to reclaim the sand to around
50% with regular mechanical attrition equipment and up to 90%
Adjustments to strip time without altering bench life
with specialised equipment. Achieving high through cure and Lower addition levels than conventional inorganic
strengths, lower addition levels - typically 2% (about half that of processes
regular inorganic binders) - can be used. This in turn improves
flowability, surface finish, and breakdown characteristics after casting.
By adding liquid hardeners of between 8% and 16% of binder
weight, the strip time can be adjusted without altering bench life.
Compared to conventional no-bake moulding processes, this new
technology has a greatly reduced environmental impact and has no
volatile organic compounds (VOC's). In addition, it produces minimal
odours or fumes on mixing, casting, or shake out.

04 www.johnwinter.co.uk
 Alkaline Phecolic No-Bake Binder - Alphaset

ALPHASET - Alkaline Phecolic No-Bake Binder

Alphaset is the original alkaline phenolic organic system binder
developed by Borden Chemicals.
Today it is still the market leader and latest developments offer
improvements in binder strength, reduced additions, lower fumes
and increased sand reclamation.
A two part system, TPA resins utilise Alphacure hardeners to give
a wide range of working and strip times for any size production facility.
We offer a full technical and calibration service for all our binders,
supported by our own laboratory and expertise of Momentive
Speciality Chemicals.

Increased strength
Improved reclamation
Improved work tie to set time ratio
Good strip characteristics
Reduced pattern cleaning times
Low odour at instigation
Low chemical toxicity

Call us for further enquiries or immediate phone orders on +44 (0)1422 364 213 05
Sodium Silicate Sand Binders

SODIUM SILICATE SANDBINDERS Sodium Silicate Binders

John Winter is the only remaining foundry supplier to produce Grade Ratio CO2 Ester Recommended Usage
a range of proprietary sodium silicate sand binders in the UK.
WB5 2.0:1 Moulds and cores - lower cost version
Suitable for mould and core making, selection of the right binder
system for casting production is possible whether for CO gas or WB10 2.5:1 Moulds and cores lower cost version
organic ester curing. WB20 2.5:1 Moulds and cores - good breakdown
Alongside Geopol, this is a low gas producing type of binder and is WB30 2.2:1 Moulds and cores - good breakdown
especially suited to gas sensitive alloys (eg: Gunmetal).
WB75 2.0:1 Moulds- higher strength, good breakdown & storage

Grade Bench Life (mins) Grade Bench Life (mins)

WS 100 2 WS 40 20
WS 80 5 WS 30 30
WS 70 7 WS 20 45
WS 60 10

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 Sand Binders

Sigmaset 8000 Series No-Bake Binder

This is a low odour aliphatic polyol no-bake system for aluminium
applications for mould and core production.
A three component system, utilising Sigmaset 8100 polyol based
urethane (Part 1), polymeric Sigmaset 8200 MDI type isocyanate
(Part 2) and one of a range of catalysts (Part 3).
It is recommended for aluminium applications requiring maximum
cold strength with the necessary breakdown characteristics and
casting surface finish.

Corovit Oil
Corovit oil is a cold setting sand binder for the manufacturer of cores.
It has the same general field of applications as cold set resins except
that in most applications the cores are ovendried.

Call us for further enquiries or immediate phone orders on +44 (0)1422 364 213 07
Sands

Silica Sand
This is the standard material for most mould and core making processes and can be used with any binder type.
Several grades are available, but the most common sizes used are AFS 60 and AFS 80.

DM Red Sand
DM Red Sand is a naturally occurring sand containing clay and water and is used for greensand moulding. The patterns are often faced with
an oil bonded sand to give an improved surface finish.

Zircon Sand
Graded, naturally occurring sand suitable for moulds and cores requiring high resistance to metal temperature. Typical grain sizing AFS 110.

Chromite Sand
Chromite sand is used for moulds and cores requiring high resistance to metal temperature. Typical grain sizing AFS 50.

Silica Carbide Chill Mix

A blend of fine SiC granules supplied as a dry mix which is used in conjunction with any binder.
It is applied locally during moulding for the chilling of the casting face for improved solidification.

08 www.johnwinter.co.uk
 Oil Bonded Sand

OIL BONDED SAND

As the only producer of oil bonded moulding sand in the UK, John Winter Co. Ltd offers a range of fine oil bonded sands which are used
to create a superior casting finish.
There are three brands available - Bentomix, Petrobond and Mansbond each with their own distinct properties.

Green Strength
Grade lbs/in2 kgs/cm2

Bentomix T 5.5-6.5 0.386-0.456

Bentomix G 7.0-8.0 0.492-0.562

Bentomix STD 7.5-9.0 0.527-0.632

Petrobond No.9 9.0-10.5 0.632-0.738

Bentomix Extra Oil 9.5-12.0 0.668-0.843

Mansbond No. 2 6.0-7.9 0.421-0.555

Grade selection will depend on the type of casting being produced

and personal preference.

Call us for further enquiries or immediate phone orders on +44 (0)1422 364 213 09
SC#2 Green Sand Conditioner
SC#2 GREEN SAND CONDITIONER
The favoured method of manufacturing large quantities of sand
castings has for many years been the use of a self contained
greensand moulding plant; re-using the sand in the system time and
time again.
Whilst these sand systems generally maintain high levels of casting
production and quality, improvements can often be made.
Sand Conditioner No.2 (SC#2) is a formulated sand additive which,
when added in small controlled levels, improves both the quality and
performance of greensand moulding systems.
SC#2 is a free-flowing powder and mixes very easily with the sand.
It is typically added as part of a pre-blend or directly at the mill via
a powder feeder. For trial purposes, or specific batch use, it can
also be added by hand directly to the mixer or even to the return
sand belt.
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SC#2 offers the following benefits:
SC#2 provides greater toughness to the mix. The sand can
therefore deform more easily without fracture - enabling the
mould to strip from difficult pockets in the pattern without pieces
breaking off due to brittleness.
The mould has more pronounced and less friable surfaces and
edges when air drying takes place during coring up or line
stoppages.
Better quality moulds in turn lead to a better casting surface finish
and dimensional accuracy.
The sand mixture is more tolerant to change in casting size (i.e.
short runs of castings varying in weight) without having to change
the clay or moisture content.
SC#2 avoids scabbing on flat surfaces of castings.
The problem of hot returned sand affects many foundries
producing large heavy section castings and without effective
cooling can lead to the following problems:
Higher moisture content requirement
Stripping difficulties from pattern
Poor compaction
Brittle sand and poor mouldability
Friable moulds
Dull casting finish and increased rework
The small addition of SC#2 eliminates all these problems.
www.johnwinter.co.uk
 AF#2M & AF#2MG

AF#2M & AF#2MG

AF#2M and AF#2MG are powdered sand additives specifically
developed to eliminate expansion defects caused by silica sand.
These defects are typically found in a wide range of castings such as
turbochargers, manifolds, axle housings and pumps when using
PUCB binders.
The addition of either grade offers visual traceability through
colouring the core either red (AF#2M) or green (AF#2MG).
Small additions to the core sand of typically 0.5% - 1.0% at the sand
mixing stage have been proven to eliminate veining, even in the
most severe cases.
Apart from the obvious benefits of reducing scrap castings, adding
AF#2M or AF#2MG at the core manufacture stage will increase
flowability of the mixed sand, improve compaction and definition of
the core and reduce blowing pressures/times.
In certain applications, reduction of the use of coatings is possible as
AF#2M and AF#2MG can be used in conjunction with finer sand
grades. This reduces the effects of metal penetration, where high
levels of veining would be found.

Call us for further enquiries or immediate phone orders on +44 (0)1422 364 213 11
Sand Additives

Kofilm 50 Sand Inhibitor Magnesium Alloys

Formerly known under the trade name Pan-X-Trol, this starch based Powdered sand additives for use with chemically bonded moulding
material is added to greensand to prevent expansion defects such as sand that will prevent a metal mould reaction. There are two grades
scabbing and rat-tailing on large flat surfaces. It is especially effective available, both of which colour the sand to ensure the addition has
in aluminium casting. been made..

Clay Binders
A range of powdered clay products for greensand moulding systems
to improve the green strength of moulds.

Coaldust
Coaldust is added to greensand for casting certain alloy types
(eg: iron, bronze) producing lustrous carbon to improve sand peel
and casting surface finish.

12 www.johnwinter.co.uk
 Parting Fluid 875

PARTING FLUID 875

Parting Fluid 875 is a highly effective pattern release used in all types
of greensand moulding.
It has been specifically developed for high production moulding
machines such as Disa, KW, HWS, Savelli, Hunter etc.
The material is sprayed onto the pattern surface, ideally as a vapour,
in very small amounts and in many cases reduction in use against
other release agents is possible.
It can also be sprayed manually where an automatic spray unit is not
fitted.
Using Parting Fluid 875 brings the following benefits:
Improved pattern strip
Low odour
Improved operator environment
High flashpoint
Safe for transportation and storage

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Release Agents

Silicone Emulsion Releasal

This water based silicone emulsion is designed for use in hot core Aluminium powder in solvent especially suitable for the release of
and mould processes for the effective release of moulds and cores furan resin moulds from the pattern although can be used for any
from the patterns. no bake system.
PF820 Dilution rates up to 20:1
PF806 Dilution rates up to 10:1 Trigel HD
A thick aluminium powder gel designed for use on continuous mixer
PF806D Ready to use troughs and blades. Trigel HD aids the removal of sand and cleaning
as part of a mixer cleaning program.
Parting Powder Aerosols
A calcium carbonate based powder for use on greensand moulds
Silicone based release agents for the effective removal of cores from
and patterns to aid release and mould separation, usually added with
the core box during production.
a dust bag or by dry brush.
Demotex A - Cold processes (eg PUCB)
Plumbago Unisil - Hot processes (eg RCS)
A graphite powder for use on patterns and coreboxes when
experiencing difficulties in lifting moulds and cores.

JW Parting Agent
Developed for all no bake systems this gives excellent pattern strip
characteristics for moulds and cores.

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GZA4
GZA4 contains zircon and graphite. This coating is suitable on
moulds and cores for most alloy types. It gives an excellent casting
surface finish and prevents metal penetration especially for non-
ferrous applications.
GZA4 is available as a paste or ready to use slurry and can be applied
by brush, swab, spray or dip.
Call us for further enquiries or immediate phone orders on +44 (0)1422 364 213
Mould & Core Coatings
Zircote
Zircote is a high level zircon refractory coating suitable for high
temperature mould and core applications such as iron and steel.
Zircote is recommended for application by brush, dip or swab.
Koalid 4087
Koalid 4087 contains alumino-silicates and has been developed for
iron applications of any section thickness for all binder type.
This coating is recommended for PUCB core manufacture.
Koalid 4087 is applied by dipping.
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Core Repair & Mould Sealant

Core Putty Moldseel 4

Water based air drying product for general repair and joint flashing Moldseel 4 is a heavy-duty mould joint sealant and is supplied in
for all types of core production. mastic tubes. It is used for mould jointing applications and is
Available in two grades: applied with a standard mastic applicator.

Standard For general repairs to cores and moulds Dikaflex

Zircon Ideal for higher temperature steel applications Dikaflex is a ready to use mould joint sealer supplied in varying
diameters; 3mm, 5mm, 6mm, 9mm and 12mm.

16 www.johnwinter.co.uk
 Adhesives

Quick Dry Standard (QDS)

This silicate based adhesive is ideal for cold core assembly, core
location and is used widely as a cope seal on mould joints.
Winfix
This acetone based adhesive is ideal for cold core assembly and core
setting into the mould with fast air drying.

Shellglue N
Shellglue N is an adhesive for RCS mould jointing and RCS core
assembly. The adhesive is cured with the heat generated by the
production process, typically >200C.

WB Shellglue
This water based shellglue is for RCS mould jointing without the use
of an oil based adhesive and is cured at normal RCS process
temperatures.

Hot Melt
We offer a range of Tecbond hot melt adhesive application guns and
Tecbond glue cartridges for rapid core assembly.

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Sleeves

A wide range of insulating and exothermic riser sleeves in any shape Breaker Cores/Cracker Wedges
and size:
RCS breaker cores which are glued on to the base of the sleeve to
aid knock-off after casting. Sleeves can be supplied with breaker
Insulating cores ready fitted. Integral cracker wedges can be supplied separately
Bimex 400 ideal for standard insulating or already fitted in the sleeve.

Bimex 400A slightly denser and offering improved insulation Pouring Cups/Bushes/Downsprues
Bimex 200 body soluble fibre for aluminium casting Offered in numerous shapes and sizes, including filter retainers for
direct casting.
Bimex 230 body soluble fibre for iron and copper casting
Bimex 820 contains inhibitor for Mg casting Tap-out Cones
A range of conical fibre pieces used in the production of primary and
Exothermic secondary aluminium applications.
Bimex 369 highly exothermic
Bimex 300 ideal for larger feeder heads
Both insulating and exothermic sleeves are available as standard
open, modern domes with or without cracker wedge and oval.

18 www.johnwinter.co.uk
 Metal Filtration

Filtration of molten metal is widely used to exert a considerable effect Filter Cloth
on the quality of castings, removing unwanted inclusions which can
Resin coated flexible filtration material, used when pouring
cause mechanical failure of the finished component.
aluminium in sand and gravity die-casting.
We have several types of filter available:
Two sizes available:
977C 490mm wide roll, 3mm mesh
Foam Filter
877F 510mm wide Roll, 1.5mm mesh
Available in different grades dependent on the metal being poured,
they have a foam-like structure with continuous pores.
There are three grades available:
Silicon Carbide Aluminium, Bronze, Iron.
Low Density Aluminium only.
Zirconia Steel.
A full range of dimension and pore sizes are available.

Round Hole Filter

Pressed, high strength filter with uniform round holes. Dimensional
stability leads to consistent pour times and mechanical stability makes
them better suited to large pour heights and weights.

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Refractory Products

Crucibles Furnace & Ladle Repair Materials

A range of graphite and silicon carbide crucibles for all alloy and melt
applications in all shapes and sizes.
Caldepatch PB 82U
Coarse ready mixed alumina based repair material suitable for the
replacement of large areas of refractory material in ladles and
Ladle Bowls furnaces. Maximum recommended temperature 1600C.
Graphite ladle bowls offer a cleaner way of removing surface slag
from the melt and can reduce or eliminate the need for slag
Caldepatch PT 88U
coagulant which can lead to inclusions. Fine ready mixed alumina based repair material suitable for repair
and patching of smaller areas of refractory in ladles and furnaces,
maximum recommended temperature 1650C.
Insulfrax Fibre Blanket
This material is used for insulation on a ladle, furnace or during
furnace construction.
Caldetrowel HQ95
Ready to use jointing mixture with a maximum recommended
With a maximum heat capacity of 1200C, Insulfrax has high handling temperature of 1650C.
strength and is made of body soluble fibre (AES wools).

Castable 1600
A low iron castable cement with a maximum working temperature
up to 1600C with very good thermal shock and slag resistance.

Gannister
Ready mixed silica based refractory/ lining material supplied in
smooth and coarse grades for use in ladles and furnaces.

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SLAGCURE K
Slagcure K powder is an additive for ferrous alloys to allow control
over slag generation and build up in furnaces and ladles.
Incorporation of Slagcure K powder with the charge, or as a ladle
addition, can greatly improve melting efficiency and metal quality
by reducing entrained slags.
Slagcure K works by decreasing slag fluidity, reducing slag melting
temperatures and the slags surface tensions to allow removal of
emulsified liquid slag particles. These particles are difficult to remove
using ceramic filters.
Call us for further enquiries or immediate phone orders on +44 (0)1422 364 213
Slagcure K
Adding fluxes during melting and metal handling is a fundamentally
important and often ignored metallurgical practice by todays
foundry. Slagcure K powder is a buffered flux that is not harmful
to refractories and furnace linings when used in the prescribed
manner.
Recommended addition rates are 0.25 Kg to 0.5 Kg per tonne of
metal to be treated. Slagcure K can be added directly to furnaces
or in the ladle prior to metal pouring.
It is especially useful for SG (Ductile) iron treatment ladles where
oxides are deposited from the reaction with the magnesium
metal treatment.
The formulation consists of a blend of oxides and does not contain
any fluorides which are harmful to both the refractory lining
and operator.
Slagcure K can be used successfully in furnaces without the fear of
attacking and reducing lining life.
Case studies are available.
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Fluxes

Aluminium Alloys Ferrous Alloys

A range of melt and treatment products are available for all grades
of aluminium: Name Use
Slagcure K Slag conditioner for iron and steel alloys
Name Use Slag Coagulant Service slag removal
Ecoflux 146 Melting/Degassing
Linofeed 470 Hot topping compound
Cover 134 Melting/Degassing in lower temperature
grade EXF 377 Hot topping compound (not classified)

Cover 302 Melting/Degassing Na Free

Ecogas 16 Degassing - Hydrogen removal
HMC 15 Na Modification powder
Injection Flux 618 Na Modification injection grade
Sodimod 28 Na Modification metallic
Verdux SH10 Na Modification tablet
Stronal Sv Modification metallic
Grain Refiner #3 Grain Refiner
Diecasting Flux 17 Re-gassing gravity dies
DeMagger B Mg removal
EXF 323 Hot Topping Compound
EXF 372 Hot Topping Compound low fumes

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 Fluxes

Magnesium Alloys Zinc Alloys

Name Use Name Use

HMC 24 Refining and protective flux Cover 2LT Drossing Flux
P.F.B Refining and protective flux
Nil Flame Dusting powder for casting

Copper Alloys
A range of melt and treatment products for all grades of copper
alloys:

Name Use
Cuprocover B503 Refining flux for brasses
Cuprocover B505 Reducing flux for commercial and
HC copper
Oxycover 501P Oxidising flux
Aluminium Remover Removal of aluminium
CT Tubes De-oxidation
Codegas 137 De-oxidation aluminium bronze
Linofeed 460 Hot Topping - copper alloys
Exofeed AL412 Hot Topping aluminium bronze

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Die Coatings

Dytek 1 Condalu 51
Highly insulating die dressing for aluminium gravity die casting. A high quality release agent containing boron nitride, Condalu 51 is
Available in coarse and fine grades. used for ingot release for primary/secondary aluminium production.

Brad-Chem 417 M Condalu 97

A water based semi-colloidal graphite dressing for gravity die casting
giving improved casting release.
Brad-Chem 401
A mineral oil based lubricant containing graphite for use on all hot
die moving components.
Water Based Zircon T
Water based ingot and sow mould coating to aid ingot release for
primary and secondary aluminium production.
Water based pigmented refractory and lubricating coating for
aluminium ingot extrusion production. Condalu 97 creates a heat
insulation coating, has good friction properties and it can also be used
as a ladle coating.
Metex
A water based paste for use as a ladle coating for aluminium ladles
and tools.

Waterbased Zircon Graphite

Water based ingot and sow mould coating to aid ingot release for
primary and secondary aluminium production.

24 www.johnwinter.co.uk
 Essential Extras

Call us for further enquiries or immediate phone orders on +44 (0)1422 364 213 25
Our Customers

Global Customers
Our constantly increasing product range and use of modern facilities keeps us at the forefront todays global foundry industry.
John Winters range of products are supported technically by our experienced sales team both on site and from our base in Halifax. We are
able to provide advice to our customers on time and cost saving methods, new technologies and best practice for a safe environment.
Over the years weve built up a dedicated network of export partners who enable us to reach out and serve 40 countries with our wide
range of specialised products.
We manufacture in the USA and our strategically positioned supply chain allows us to supply the North and Central American market.

26 www.johnwinter.co.uk
 Warehouse

Call us for further enquiries or immediate phone orders on +44 (0)1422 364 213 27
PO Box 21
Washer Lane
Halifax
West Yorkshire HX2 7DP
United Kingdom

Tel: +44 (0)1422 364 213

Fax: +44 (0)1422 330 493
email: sales@johnwinter.co.uk
web: www.johnwinter.co.uk