Job Description

Roles & Responsibilities

Department - Casting Shop Reports to - Molding Engineer Job Purpose The Sand Laboratory Testing Technician is responsible for testing new sand and samples, resin, hardener, coating materials etc. and monitoring, and controlling molding and core sand properties used in the Alpha Set (alkaline phenolic) molding process. The role ensures that sand parameters are maintained within specified limits to achieve consistency in molding sand strength, acid value to achieve defect-free castings, safe pouring operations, and cost control.

Job Responsibilities

Sand Testing & Control

• Carry out routine and day-wise testing of molding and core sand as per foundry standards.
• Test and monitor the following sand properties:
• Grain Fineness Number (GFN)
• Moisture content
• Loss on Ignition (LOI)
• pH value
• Compression / Tensile / Transverse strength
• Permeability
• Gel Time for Resin and hardener
• Gel Time
• Bench Life
• Collect sand samples from mixers, molding lines, core lines, and reclaimed sand systems .

Alpha Set Process Monitoring

• Ensure correct resin and hardener dosing as per Alpha Set process requirements.
• Monitor reclaimed sand quality and recommend fresh sand addition when required.
• Identify deviations in sand properties and immediately inform production and quality teams .
• Support molding lines and core lines teams in sand-related troubleshooting .

Quality & Defect Prevention

• Assist in root cause analysis of sand-related casting defects such as:
• Gas defects
• Blowholes and pinholes
• Mold erosion and sand wash
• Low mold or core strength
• Ensure compliance with process control limits and quality standards .

Documentation & Records

• Maintain accurate sand test records , reports, and logs shift-wise and batch-wise.
• Ensure proper documentation for ISO / QMS / customer audits .
• Update sand control charts and highlight trends or abnormalities.

Equipment & Housekeeping

• Operate and maintain sand testing equipment such as:
• Sieve shaker
• Universal sand strength testing machine
• Permeability meter
• Moisture tester
• pH meter
• Ensure calibration and proper functioning of lab equipment.
• Maintain cleanliness and safety in the sand laboratory.

Desired Candidate Profile

• Diploma / ITI in Foundry Technology, Metallurgy, Mechanical Engineering, or related field
• Basic understanding of foundry processes is mandatory
• Minimum 2-5 years of experience in sand testing in a steel foundry
• Hands-on experience with Alpha Set (alkaline phenolic) molding and core making system preferred
• Strong knowledge of: Foundry sand properties and testing methods Alpha Set resin system and curing behavior Reclaimed sand control and sand preparation systems
• Ability to interpret test results and take corrective actions
• Computer skills reporting run charts, bar charts. SPC studies for controlled sand parameter
• Good communication skills to coordinate with production and quality teams
• High attention to detail and discipline in testing frequency
• Awareness of foundry safety practices and PPE usage
• Ability to work in shift operations and shop-floor environment
• Min 5 - 7 years experience required in Steel casting & forging Plant / Casting