Precision Casting Limited (previously Foundry and Fabrication) is a member of Goonvean Group and specialises in manufacturing high-quality castings for a diverse portfolio of industries.
Precision Casting have recently completed Phase 1 of a multi-million-pound expansion programme designed to create an exceptional facility beginning with the opening of a new state-of-the-art casting operation.
Why is this investment so important?
This substantial investment will service the increasing demand in the UK casting sector. Investing in their facilities gives Precision Casting superior capacity, streamlines their operations and improves overall quality and efficiencies. Stuart Reacord, Managing Director of Precision Casting, explains: “Constrained capacity in the UK market for casting buyers, coupled with the outdated infrastructure of our previous site, made this project an absolute necessity.
Having these modernised facilities provides our customers even more assurance in trusting their business to us. The beautifully designed new building is also more appealing to local expertise, attracting trained professionals to join our expanding team.
This investment has met the needs of a demanding marketplace and secured the future growth ambitions for Precision Casting. All in all, it’s money well spent.”
Years in the making: a long-term vision finally realised
Planning for the investment began in 2020 when early discussions were triggered by the need of a new roof for the entire Precision Casting manufacturing facility. Goonvean Group formally approved the project in October 2022, planning permission was lodged in June 2023 and permission was granted in January 2024. The phased implementation of this innovative project could finally begin.
Challenges
Throughout the process, the biggest challenge for Precision Casting was ensuring the minimum of disruption to their existing client base.
Stuart Reacord said: “We are incredibly proud to have been able to maintain our production capabilities whilst completing this complex project. Throughout each phase, our clients continued to enjoy the same high-quality products and services they have grown to expect from Precision Casting.”
Highlights
One of the many project highlights included the installation of robotic Auto Fettlers; one was commissioned in November 2024, with a larger unit due for commission in April 2025.
The robots will provide repeatable, consistent grinding, increased productivity, and improved finish on manufactured castings. A new Optical Emission Spectrometer (OES) has also been installed, providing higher-performance metals analysis and improved control of material composition.
A Two-Phase Project
The new Precision Casting facility has been divided into two phases. Each phase brings new technology, additional capacity and improved capabilities to Precision Casting operations.
Phase 1
Phase 1 commenced in May 2024 and was finished in November. It included the installation of:
- A 20 tonne per hour articulated continuous mixer
- A 10 tonne per hour single-arm continuous mixer
- Two continuous loops featuring elevated mould capacity
- A floor moulding plant for producing large, low-volume, high-integrity castings up to one metric tonne
Phase 2
Phase 2 commenced in January 2025 and is on target for completion in June. It will introduce a rapid automatic moulding system, the first of its kind in the UK, and also include:
- A vertical moulding loop capable of delivering five times the previous capacity
- Ten continuous workstations
- Automated filling, stripping, and closing operations
- The most innovative no-bake moulding line in the UK
How Precision Casting customers and stakeholders benefit
This investment makes Precision Casting more competitive as they continue to address the varied needs of their client base.
Their customers and stakeholders will also benefit from:
- Reduced lead times
- Enhanced quality
- Increased flexibility
- A significant uplift in capability to produce larger, high-integrity castings
- Value-added services, including in-house toolmaking, CNC machining, painting, plating, and non-destructive testing
How Precision Casting benefit
This investment is part of a long-term strategy to position Precision Casting as a market leader. By advancing their technical capabilities, they will establish themselves as a class leader in the casting industry. This expansion cements Precision Casting’s commitment to excellence, enabling them to be a partner of choice to existing and new customers.
The project will also generate exciting career opportunities, creating positions for engineers, automation specialists, and apprentices. By investing in the workforce of the future, Precision Casting will ensure they acquire and retain the highest degree of competence in their sector.
Looking ahead
Stuart Reacord shares his thoughts for the future: “With the expansion well underway, Precision Casting shifts into a dynamic new era. We are delighted to provide the most modern, technologically sophisticated and significantly sustainable non-ferrous foundry and machining plant in the UK.
Not only will this development ensure the future of the company on a long-term basis, it also puts us in a position to serve our customers’ evolving requirements for years and generations to come.”
Matthew Gazzard, Managing Director for Goonvean Group, added his comments regarding the development: “The creation of Precision Casting Limited and the incredible facility they will operate from is an incredibly important development for the Group. It represents a significant level of trust and investment into a business which we feel is now positioned on the leading edge of sector. We are genuinely excited to see the facility completed so that we can share all of its capabilities with our customers and stakeholders.”