LOST FOAM FOUNDRY SYSTEM STAGE I

ITEM NO. 1 2 3 4 7 Sand System Line Pattern Molding Press Vacuum Pre-Expander Bead Distribution/Storage Drying Oven

ITEM NO. 11 - Cluster Coating Machine 12 - Pattern Assembly Machine 14 - Steam Accumulator 15 - Water Cooling and Recirculation System 16 - Spare Parts Package 20 - Prototype Tooling/Casting

STAGE I ITEM NO. 1 - PRODUCTION LINE SAND SYSTEM To include: Flask Conveyor System for guiding flasks between system stations. Constructed of heavy duty structural steel. Two parallel lines shall consist of auto-powered and gravity conveyor sections with transfer sections at each end. The stations to be included are: a) Sand pre-fill b) Pattern insertion and first stage fill and compaction c) Second stage fills. Sand system initially included. Second stage compaction table to be added at a late date d) Metal pouring area e) Cooling area f) Auto dump station g) Sand cooling, reclaimation and classification Thirty-six(36) dia.x 40" high flasks steel plate construction with locators for auto dumping. Quantity based on 40 minute cooling time and 40 flasks per hour production. (27 flasks in cooling, 9 flasks in fill and pour) One (1) High Frequency Compaction Table Heavy duty, low headroom, high frequency, vibratory compaction table, 42" wide x 4'0" long, complete with a solid deck and three (3) vertical compaction pedestals. FUNCTION: Compaction Table is designed to compact and condense dry. Unbonded sand to it's maximum bulk density of 108 to 111 PCF in 30 seconds. Table will handle a maximum load capacity of 2,700 lbs. Compaction Table will be designed to locate directly under sand fill station. Flasks to be powered to and from the compaction station by a conveyor system to within plus or minus 1/4". A two-position pneumatic support system will raise and lower the table to and from the flasks. Pneumatic support system will have a cycle time of 2-5 seconds.

DESCRIPTION: Deck Construction Compaction deck will be fabricated of 1" thick AISI 1020 steel to make a 43" wide x 4'-0" long one-piece solid deck arrangement. Deck will be reinforced and gusseted with structural steel members which will provide the mounting surface for two (2) heavy-duty 2-1/4 HP drive assemblies. Deck will be reinforced and gusseted with structural steel members for dimensional stability. Deck will be provided with three (3) vertical compaction pedestals complete with wear pads and arranged on special centers. Wear pads will be designed to self-align to the bottom of the flask and provide the proper engagement for controlled compaction. Wear pads will be bolted for ease of replacement and fabricated of 1" thick AR impact steel. Impact pads will be Blanchard ground to provide a flat matting surface for the flask. The 1" thick compaction deck will also be Blanchard ground to provide a flat matting surface for the vertical compaction pedestals. Drive Drive unit will be two (2) 2-1/4 HP, 3600 RPM motors rated for 220 Volt. 3 Phase, 50 Cycle power supply. Compaction Table Amplitude Table under full load: 0.028 vertical stroke (amplitude) with a 4.0 to 5.0"g" acceleration Note: Amplitude and acceleration can be manually adjusted. Isolation Compaction Table will be provided with eight (8) specially compounded rubber isolation springs. Isolation springs will be bolted directly to a lower fabricated lift frame assembly. Lift Frame Assembly Compact table will be provided with a 3-way solenoid valve providing a two-position pneumatic support system, designed to raise and lower the unit approximately 1" to 2" in 2.5 seconds. Support system will include the lower spring seats, base steel stabilizer linkage designed to elevate the deck approximately 30" above floor foundation. One (1) Elevating Flask Dump Station onto vibratory grid/transfer conveyor for casting and sand separation

One (1) Bucket Elevator for transporting sand from dump station to cooler/classifer Sand Cooler/Classifier System rated at 40 tons/hour 400 degrees F to 100 degrees F +/- 5 degrees with magneti separator Sand Fill Hopper System with rotary 'raining" device for flask filling (Return Sand Tank capacity of 17 ton) Allen Bradley 220 PC controls plus Allen Bradley T50 Computer, monitor and keyboard with online/offline programming capability - include all software and 20% spare space for future input/output additions.

COST....................................$.....TBD based upon India Manufacture to our drawings

STAGE I ITEM NO. 2 - PATTERN MOLDING PRESS TWO (2) ANTONIC MODEL PS-603B EXPANDABLE POLYSTYRENE MOLDING PRESSES BASE MACHINE Construction Rugged, unitized machine base fabricated of structural steel channel. Open access design provides ease in maintenance. Platens Stationary and moving platens are cast iron to eliminate deflection during operation. Open stationary platen with T-slotted grids can provide rapid, secure mounting of steam chest and selfcontained molds without fill gun or utility interference. Moving platen also has horizontal and vertical T-slots for rapid mold mounting and adjustment. Useable platen area is 33" x 42". Strainer Rods Four (4) 3" diameter, accurately ground steel strainer rods provide precise platen travel and alignment. Industrial chrome plated for long life. Platen Movement Machine has a stroke of 40" with a maxi- mum open daylight between platen of 56". Optional cylinder rod extensions allow changes in minimum and maximum daylight and dimensions. ELECTRICL SYSTEM Power 220 VAC, 3 Phase, 50 hertz required. Control voltages (115 VAC and 12 VDC) provided by internal transformers. Controls All panel switches and pushbuttons are full-sized, heavy-duty, oil-tight and color-coded. Programmable Cycle Allen Bradley SLC-150 Programmable Controller with 24-step cycle, individual steam and ejection control, individual temperature control and key operated lock-out for the Timer/Counter Access Access Terminal (TCAT).

HYDRAULIC SYSTEM Base System Self-contained, hydraulic system mounted on base machine frame, including 10 HP, AC motor,
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hydraulic vane pump, hydraulic fluid reservoir, filter, and hear exchanger. 2-Speed Operation A regenerative system with adjustable flow provides for 2-speed platen operation, typically a slow-fast-slow travel which minimizes platen travel time yet provides cushioning at both full "open" and full "closed". Valves, Cylinders All hydraulic valves are manifolded to reduce connections, fittings and piping and reduce maintenance. Standoff Four (4) point hydraulic standoff provides adjustable mold venting for faster filling STEAM SYSTEM Capacities 2-1/2" Steam Supply Line and 1-1/2" Valves, 2" Diameter Drains. Controls Independent fusion and dwell controls provide pressure steaming for optimum control. Separate pressure regulators, gauges and drains for moving and stationary sides. All regulators and gauges are conveniently grouped at operator control station. Safeties Air-operated drain valves act as safety reliefs to prevent over pressures. Positive steam shut-off valves provided after steam regulators.

PNEUMATICS Base system Complete pneumatic system including filter, lubricator and moisture trap. mounted on manifold. All piping of rigid copper tubing are durable nylon.

Solenoid valves

Pneumatic Control Incoming pressure regulator and gauge standard. Includes utility air regulator system for individual control of fill air, boost air, air eject (stationary and moving). FILL SYSTEM Fill Hopper One flexibin mesh hopper provides bead storage with total visibility. Zippered opening provides easy access for cleanout. Twelve (12) connections with twelve (12) feed bowls
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Bead Transport 2.0 HP blower transports bead from plant storage to Flexibin fill hopper positively and gently. Level Control Bead level sensor turns blower on and off to maintain constant bead levels in the Flexibin fill hopper for optimum fill conditions. SAFETY SYSTEM Guards Sliding guards on both sides of press provide easy access to molding area and are multiple interlocked to provide fastest possible operation. Interlock Both side guards must be fully closed to actuate the electrical interlock switch and hydraulic pilot valve to provide power and hydraulic pressure to the press. Controls Large mushroom stop buttons at each corner of press allow hydraulic motor to be instantly stopped and control power shut off from four (4) operator locations. Operator Regardless of the safeguards built into any machine, safe operation depends on safety-conscious personnel who understand the equipment and operate in accordance with the instruction manuals and safety rules provided. CYCLE TIME A typical "average" cycle of 90 second can be realized; actual time may vary depending on part and tool design, utility variances and EPS bead type and manufacturer.

COST ..................................$...TBD by Antonic

ITEM NO. 3 - VACUUM PRE-EXPANDER TWO (2) MODEL 718V DRISPANDERS - Batch type pre-expander used to pre-expand EPS material from its bulk density of 40 lb. cu. ft. to molding density between 1.1 and 1.5 lb. cu. ft. - Accuracy of the pre-expander is plus or minus 2% of the desired finished density to be molded.
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- The 718V drispander is designed to pre-expand all EPS material including "T" and "X" bead produced by chemical companies. - Construction of the unit consists of a jacketed aluminum agitator chamber supported by a steel frame. A two-bladed aluminum agitator is powered by an electric motor and gear box. The bead introduction bead discharge, vacuum pump and water metering device are controlled by remote operated air valves. All expand cycle functions are controlled by a programmable controller.

COST ....................................$....TBD by Antonic

ITEM NO. 4 - BEAD DISTRIBUTION AND STORAGE SYSTEM - The take-away unit is an aluminum hopper supported by a steel frame. There is an electric motor powered blower attached to the frame. This unit slides under the discharge chute of the drispander and transports bead from the drispander to the storage bags. - Six (6) storage bags made of small mesh fiber designed to store the smallest size beads. The bags have grounding wires sewn in all four corners. The bags are supported on iron frames. Included are take-away units for transporting bead from the bags to the press hopper.

COST ............................$TBD by Antonic

ITEM NO. 5 - BOILER AND FEED WATER SYSTEM Antonic, Inc shall provide full specifications to purchase this item locally.

ITEM NO. 6 - AIR COMPRESSOR Antonic, Inc shall provide full specifications to purchase this item locally.

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ITEM NO. 7 - DRYING OVENS Two (2) Drying Ovens One (1) Pattern Aging Oven, 7' wide, 20' deep, 7'high One (1) Cluster Drying Oven, 7' wide, 20' deep, 7' high The oven produces indirect heated air which is moved around the foam patterns and wash coated clusters by a blower system. The air within the oven is exchanged eight to twelve times per hour. After approximately 4 to 6 hours, the clusters are dry and ready for insertion into the sand flasks.

COST .............................. $..TBD by Antonic

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ITEM NO. 11 - CLUSTER COATING MACHINE One (1) PRODUCTION DIPPING ROBOT SYSTEM 4-Axis with DC drives and control systems. Approximately 3 minutes cycle time, with 20 cluster (flasks) per hour capacity. Robot load capacity of 120 lbs., including tooling

COST .....................................$...TBD by Antonic

ITEM NO. 12 - PATTERN ASSEMBLY MACHINE One (1) PA-2 PATTERN ASSEMBLY MACHINE A three (3) station hot melt gluing machine to accept multiple part EPS foam patterns two pieces at a time. This machine requires the use of fixtures to hold the EPS foam patterns in place and requires the operator to index the fixture through a detent system to each station and initiate the printing of glue and alignment of pattern pieces. Cycle 40 seconds to 1 minute.

COST ...................................$....TBD by Antonic

ITEM NO. 14 - STEAM ACCUMULATOR A steam accumulator, as the name implies, accumulates energy to be supplied to the molding equipment in relatively large quantities intermittently. The wet steam accumulator also acts as buffer in the steam system and protects the boiler from potentially dangerous pressure swings, enabling the boiler to replace the energy in the accumulator on an even and continuous basis.

COST ...................................$...TBD by Antonic

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ITEM NO. 15 - ONE (1) WATER COOLING SYSTEM: Rated at 100 GPM @ 100 PSI, 145 degrees F. tower inlet, 85 degrees tower discharge to include: One (1) 3 HP sump pump set, pumping system return water from customer sump to system hot tank One (1) 5 HP hot tank pump set, pumping system return from hot tank to cooling tower One (1) 15 HP cold tank pump set, pumping system process water from cold tank to process One (1) each hot tank, cold tank assembly, each to include: Double welded heavy-duty steel construction 1200 gallon holding capacity structural support frame. (4) 7' support legs (shipped loose), exterior enamel painting, interior epoxy lining, pre-piped pump trim, suction shutoff butterfly valve, increasers as required, discharge check valve, discharge balancing butterfly valve, compound pressure gauge, fittings as required, spool assemblies, unions and fittings as required, valve drain connection, plugged future pump connections, equalizing line connection, stainless strainer basket, thermometer. Hot tank only also includes: Ball floats make-up valve, fittings, shut-off and baffles, overflow connection. Cold tank only also includes; Pressure regulating valve, fittings and shut-off gate valve (mounted on side of tank). One (1) 20 HP forced draft cooling tower to include: Forced draft design, hot-dip galvanized construction, large orifice, removable spray nozzle, PVCwet deck, overspray eliminator, zinc chromatized aluminum paint finish, squirrel cage blower(s), drip-proof fan motor(s), thermostatically controlled automatic capacity control dampers, magnetic motor starter(s) in NEMA-1 enclosure(s) with stop and start pushbuttons and overload protection (shipped loose). One (1) automatic water strainer, .010 solids removal with automatic backwash control

TOTAL SYSTEM COST ..................$...TBD by Antonic

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ITEM 16 - SPARE PARTS PACKAGE Spare parts packages, including replacement parts, service kits and rebuilding kits, and rebuilding kits shall be provided for each of the following equipment packages: Production Line Sand System $..All TBD by Antonic PS-603B Molding Press (2)* 718V Drispander (1)* Bead Take-Away and bags Cluster and Pattern Oven Shell-O-Matic Dipping Unit Pattern Assembly Machine (1)* Accumulator Water Cooling System ---------TOTAL SPARE PARTS PACKAGE ESTIMATE: $....TBD by Antonic

* Designates number of machines covered by Spare Parts Package.

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ITEM NO. 17 - ENGINEERING AND INSTALLATION PACKAGE

1. Floor plans and elevation layouts showing equipment locations in customer's plant. 2. Plumbing diagrams showing all required piping for installing machinery. Diagrams include locations and sizes for all valves, shut-off valve, and steam traps, etc., required for installation of all equipment. 3. Antonic,Inc., will also provide on-site supervision of installation of the equipment described above and provide start-up and personnel training services for up to one (3) months. 4. Equipment identification and tagging of components by key numbering system to facilitate ease in set-up and installation. Antonic, Inc.,will provide advisory and consulting services to Purchaser's contractors, by internet or telephone. If additional personnel visit is required, additional charges may apply. 5. Antonic Inc., servicemen, for three weeks at customer's plant, to train personnel in equipment operation and maintenance. 6. Operation and maintenance manuals for all equipment, including electrical, pneumatic and hydraulic schematics. 7. Two day serviceman follow-up visit, two to three months after installation of all equipment

COST ...............................$....TBD by Antonic

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ANTONIC & ASSOCIATES

LOST FOAM FOUNDRY SYSTEM

STAGE II

ITEM NO. 1 - Sand System Line (Compaction Table) " " 2 - Pattern Molding Press " " 11 - Cluster Coating Machine " " 12 - Pattern Assembly Machine " " 13 - Cluster Assembly Machine

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STAGE II ITEM NO. 1 HIGH FREQUENCY COMPACTION TABLE One (1) High Frequency Compaction Table Heavy duty, low headroom, high frequency, vibratory compaction table, 42' wide x 4'0" long, complete with a solid deck and three (3) vertical compaction pedestals. FUNCTION: Compaction Table is designed to compact and condense dry, unbonded sand to its maximum bulk density of 108 to 111 PCF in 30 seconds. Table will handle a maximum load capacity of 2,700 lbs. Compaction Table will be designed to locate directly under sand fill station. Flasks to be powered to and from the compaction station by a conveyor system to within plus or minus 1/4". A two-position pneumatic support system will raise and lower the table to and from the flasks. Pneumatic support system will have a cycle time of 2.5 seconds. DESCRIPTION: Deck Construction Compaction deck will be fabricated of 1" thick AISI 1020 steel to make a 43" wide x 4'-0" long one-piece solid deck arrangement. Deck will be reinforced and gusseted with structural steel members which will provide the mounting surface for two (2) heavy-duty 2-1/4 HP drive assemblies. Deck will be reinforced and gusseted with structural steel members for dimensional stability. Deck will be provided with three (3) vertical compaction pedestals complete with wear pads and arranged on special centers. Wear pads will be designed to self-align to the bottom of the flask and provide the proper engagement for controlled compaction. Wear pads will be bolted for ease of replacement and fabricated of 1" thick AR impact steel. Impact pads will be Blanchard ground to provide a flat matting surface for the flask. The 1" thick compaction deck will also be Blanchard ground to provide a flat matting surface for the vertical compaction pedestals.

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Drive Drive unit will be two (2) 2-1/4 HP. 3600 RPM motors rated for 220 Volt, 3 Phase, and 50 Cycle power supply. Compaction Table Amplitude Table under full load: 0.028 vertical stroke (amplitude) with a 4.0 to 5.0 "g" acceleration Note: Amplitude and acceleration can be manually adjusted. Isolation Compaction Table will be provided with eight (8) specially compounded rubber isolation springs. Isolation springs will be bolted directly to a lower fabricated lift frame assembly. Lift Frame Assembly Compaction Table will be provided with a 3-way solenoid valve providing a two-position pneumatic support system, designed to raise and lower the unit approximately 1" to 2" in 2.5 seconds. Support system will include the lower spring seats, base steel stabilizer linkage designed to elevate the deck approximately 30" above floor foundation.

COST .............................$94,242.00

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ITEM NO. 2 - PATTERN MOLDING PRESS TWO (2) KOHLER GENERAL MODEL PS-603B EXPANDABLE POLYSTYRENE MOLDING PRESSES BASE MACHINE Construction Rugged, unitized machine base fabricated of structural steel channel. Open access design provides ease in maintenance. Platens Stationary and moving platens are cast iron to eliminate deflection during operation. Open stationary platen with T- slotted grids can provide rapid, secure mounting of steam chest and self- contained molds without fill gun or utility interference. Moving platen also has horizontal and vertical T-slots for rapid mold mounting and adjustment. Useable platen area is 33" x 42". Strainer Rods Four (4) 3" diameter, accurately ground steel strainer rods provide precise platen travel and alignment. Industrial chrome plated for long life. Platen Movement Machine has a stroke of 40" with a maximum open daylight between platen of 56". Optional cylinder rod extensions allow changes in minimum and maximum daylight and dimensions.

ELECTRICAL SYSTEM Power 220 VAC. 3 Phase, 50 hertz required. Control voltages (115 VAC and 12 VDC) provided by internal transformers. Control color-coded. All panel switches and pushbuttons are full-sized, heavy duty, oil-tight and

Programmable Cycle Allen Bradley SLC-150 Programmable ControllerController Controller with 24-step cycle, individual steam and ejection control, individual temperature control and key operated lock-out for the Timer/Counter Access Terminal (TCAT).

HYDRAULIC SYSTEM Base System Self-contained, hydraulic system mounted frame, including 10 HP, AC motor, hydraulic vane pump, hydraulic on base Machine

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fluid reservoir, filter, and heat exchanger. 2-Speed Operation A regenerative system with adjustable flow provides for 2-speed platen operation, typicallP a slow-fast-slow travel which minimizes platen travel time yet provides cushioning at both full "open" and full "closed". Valves, Cylinders All hydraulic valves are manifolded to reduce connections, fittings and piping and reduce maintenance. Standoff filling. STEAM SYSTEM Capacities 2-1/2" Steam Supply Lines and 1-1/2" Valves 2" Diameter Drains. Four (4) point hydraulic standoff provides adjustable mold venting for faster

Controls Independent fusion and dwell controls provide pressure steaming for optimum control. Separate pressure regulators, gauges and drains for moving and stationary sides. All regulators and gauges are conveniently grouped at operator control station. Safeties Air-operated drain valves act as safety reliefs to prevent over pressures. Positive steam shut-off valves provided after steam regulators. PNEUMATICS Base System Complete pneumatic system, including filter, lubricator and moisture, trap. Solenoid valves mounted on manifold. All piping of rigid copper tubing or durable nylon. Pneumatic Control Incoming pressure regulator and gauge standard. Including utility air regulator system for individual control of fill air, boost air, air eject (stationary and moving). FILL SYSTEM Fill Hopper One flexibin mesh hopper provides bead storage with total visibility. Zippered opening provides easy access for cleanout. Twelve (12) connections with twelve (12) feed bowls. Bead Transport 2.0 HP blower transports bead from plant fill hopper positively and gently. storage to Flexibin

Level Control Bead level sensor turns blower on and off to maintain constant bead levels in the Flexibin fill hopper for optimum fill conditions. SAFETY SYSTEM
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Guards Sliding guards on both sides of press provide easy access to molding area and are multiple interlocked to provide fastest possible operation. Interlocks Both side guards must be fully closed to actuate the electrical interlock switch and hydraulic pilot valve to provide power and hydraulic pressure to the press. Controls Large mushroom stop buttons at each corner of press allow hydraulic motor to be instantly stopped and control power shut off from four (4) operator locations. Operator Regardless of the safeguards built into any machine, safe operation depends on safety-conscious personnel who understand the equipment and operate in accordance with the instruction manuals and safety rules provided. CYCLE TIME A typical "average" cycle of 90 seconds can be realized; actual time may vary depending on part and tool design,utility variances and EPS bead type and manufacturer.

COST ...................................$177,100.00

ITEM NO. 11 - CLUSTER COATING MACHINE One (1) PRODUCTION DIPPING ROBOT SYSTEM 4-Axis with DC drives and control systems. Approximately 3 minutes cycle time, with 20 cluster (flasks) per hour capacity. Robot load capacity of 120 lbs., including tooling.

COST ...............................$77,165.00

ITEM NO. 12 - PATTERN ASSEMBLY MACHINE One (1) PA-2 PATTERN ASSEMBLY MACHINE A three (3) station hot melt gluing machine to accept multiple part EPS foam patterns two pieces at a time. This machine requires the use of fixtures to hold the EPS foam patterns in place and requires the operator to index the fixture through a detent system to each station and initiate the printing of glue and alignment of pattern pieces.

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COST ..................................$53,130.00 Tooling and fixtures are excluded from this quote and will be quoted when the product mix is finalized. Estimated tooling and fixtures are $5,000.00 per part.

ITEM NO. 13 - CLUSTER ASSEMBLY MACHINE A three (3) station, automatic cluster assembly machine to assemble foam pieces into cluster assemblies. Manual load and unload. Operator interface needed for quality control.

COST ...............................$137,885.00

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S T A G E II

TOTAL BUDGETARY COSTING

ITEM NO. 1 - Compaction Table " " 2 - Pattern Molding Press " " 11 - Cluster Coating Machine " " 12 - Pattern Assembly Machine " " 13 - Cluster Assembly Machine ----------STAGE II TOTAL COST

$ 94,242.00 177,100.00 77,165.00 53,130.00 137,885.00

$539,522.00

Normal service charges will apply for set-up and acceptance of equipment under Stage III. Anticipated to be $500.00 per day plus travel and living expenses.

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ANTONIC & ASSOCIATES

LOST FOAM FOUNDRY SYSTEM

STAGE III

INCLUDING

ITEM NO. 10 - Robot ITEM NO. 19 - Overhead Conveyor System

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STAGE III ITEM NO. 10 - ROBOT One (1) GMF M-100 Robot - Three (3) - 3 or 5 axes of motion - 50 kg (110 lbs.) payload - Plus or minus 0.5mm repeatability - 300 degree base rotation - 550mm (21.5") vertical travel (optional 1300mm, 51.2") - 500mm (19.7") horizontal travel (optional reach up to 1100mm (43.3")) - Forklift provisions

COST ..............................$94,875.00

Normal service charges will apply for set-up and acceptance of equipment under Stage III. Anticipated to be $500.00 per day plus travel and living expenses.

ITEM NO. 19 - OVERHEAD CONVEYOR SYSTEM Power conveyor for conveying of coated pattern clusters away from the coating area and through the cluster drying oven. Variable speed drives to allow for 2 hour oven residence time.

COST .............................$73,370.00

Above cost includes installation supervision at customer's plant for a maximum of two weeks. Customer to supply labour.

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S T A G E III TOTAL BUDGETARY COSTING

ITEM NO. 10 - ROBOT

$94,875.00 73,370.00

ITEM NO. 19 - OVERHEAD CONVEYOR SYSTEM ----------STAGE III TOTAL COST $168,245.00

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A PRODUCTION LOST FOAM FOUNDRY SYSTEM FOR GREY IRON WITH ULTIMATE CAPACITY OF 40 FLASKS/ HOUR

BUDGETARY COSTING

STAGE I .............................. $1,870,134.00 STAGE II................................ $539,522.00 STAGE III .................................$168,245.00

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