Capabilities

Today equipment manufacturers are challenged with competing in a global marketplace. As industry has globalized, companies face increased pressure to reduce costs. We partner with them to continuously improve – providing greater expertise and flexibility.

Capabilities ultimately define how well foundries and manufacturers of machined components are equipped to meet the needs of OEMs in the markets they serve. Creating capabilities that match well with the requirements of specific markets is not limited to plant and equipment. While many foundries offer a range of abilities, few offer the full array of services we provide – matched with quality certifications and complete on-site pattern, casting, machining, testing, and assembly capabilities. As the following chart shows, the synergy of people and their skills, processes, and the right equipment creates superior capabilities at Calco.

The C.A. Lawton Equipment Capabilities

Pattern-Making Capabilities

  • Precision CNC foam, wood, and urethane patterns up to 150” square
  • Full solid modeling and metal-flow simulation services

Foundry Capabilities

  • Gray ASTM A48 Class 30 to 50
  • Ductile ASTM A536 60-40-18 to 100-70-03
  • Austemper as well as specially irons available
  • 400 – 15,000 pound castings
  • ISO 9001 : 2008 Certified
  • In-mold as well as furnace heat-treating
  • ASME Pressure Vessel and ABS Certified
  • Chemical and Mechanical Certifications
  • Non-Destructive testing
  • Paint
CA Lawton Capabilities Image

Machining Capabilities

CNC Vertical Turning Centers

  • Minimum OD: 20″
  • Maximum OD: 150″
  • Max Length: 90″
  • Max Weight: 20,000 LBs

Boring Mills

  • Max Travel: Y – 103″ , X – 142″, W – 59″
  • Max Weight: 20,000 LBs

Misc Capabilities

  • Key seating
  • Radial Drills
  • Static and Dynamic Balancing
  • Assembly
  • Hydro-Testing
  • ASME Pressure Vessel and ABS Certified
  • Faro Arm CMM

machining-capabilities

Integrated Manufacturing

Today equipment manufacturers are challenged with competing in a global marketplace. As industry has globalized, companies face increased pressure to reduce costs. We partner with them to continuously improve – providing greater expertise and flexibility.

Capabilities ultimately define how well foundries and manufacturers of machined components are equipped to meet the needs of OEMs in the markets they serve. Creating capabilities that match well with the requirements of specific markets is not limited to plant and equipment. While many foundries offer a range of abilities, few offer the full array of services we provide – matched with quality certifications and complete on-site pattern, casting, machining, testing, and assembly capabilities. As the following chart shows, the synergy of people and their skills, processes, and the right equipment creates superior capabilities at Calco.

Understanding the relationship between pattern, casting, machining, testing, assembly and single-source accountability is only the beginning. We have extensive experience in all of these areas – and we do them all at one location.

Our integrated services begin with understanding customer requirements, from specifications and tolerances to quantities and delivery dates. Coordination is the key to integration, and it begins with the integrated scheduling process that starts each day at Calco.

We understand what it takes to manage the production of large castings and large machined components. It’s one of the primary ways we make buying castings easier. For our customers who look for opportunities to consolidate suppliers or the combined savings from coordinating purchasing, inventory, and logistics, we’re an excellent resource for casting solutions.

For a manufacturing consultation, call us today at 920-337-2470.
Integrated-Manufacturing.

Iron Castings

Quality castings that provide the strength and design integrity for equipment in the most demanding applications in the world are the centerpiece of our product offering.

Because of strict controls and adherence to process, we’ve developed into one of the best large casting iron and ductile iron foundries in North America. Attention to strict control ranges from careful selection of raw materials and maintenance of the very best melt practices to tight sand controls and documentation of processes and practices in the molding process.

Calco has produced castings and machined components for five generations. This, combined with technical support and unparalleled communication, continues to be our primary focus for innovation and growth.

For an iron casting consultation, call us today at 920-337-2470.

Iron-Castings

Machining

Our on-site machine shop is built on a long legacy of providing industrial components to markets such as paper and power transmission. In recent years we have invested and worked to broaden our capabilities and the markets we serve. Today machining is not only an important part of our business but a critical piece of the value proposition we provide our customers. We offer integrated or turnkey solutions for machined components.

Providing castings machined in the facilities at Calco or sourced from a supplier partner is a central element in our goal to simplify the casting buying process for our customers.

For a machining consultation, call us today at 920-337-2470.

Machining

Patterns

It’s impossible to overstate the value of patterns to the success of the casting process. Because patterns ultimately determine the shape and dimensional accuracy of the casting and contribute to iron integrity, Calco maintains an on-site, state-of-the-art pattern operation.

Successful pattern design balances an intimate knowledge of the casting process, annual volume, investment, and material selection. Large castings can be produced from patterns (up to 150” square) made from many materials, and at Calco the variety ranges from foam for prototypes or single-use castings to multiple types of wood and urethane, depending on the application and the volume.

Our pattern operation provides critical support to the casting operation by combining technology, craftsmanship, and understanding of the rigors of the casting process.

For a pattern consultation, call us today at 920-337-2470.

Patterns

Engineering

As OEMs push to improve their businesses, they expect more from their supplier partners. From productivity improvements to increasingly complex grades of iron and converting fabrications, castings and machined components are consistently the target for optimization. As part of our commitment to continuously add value, we provide engineering support to our customers.

For Calco, customer support begins with the new job start-up process. We use a cross-functional team comprised of tooling and casting engineers as well as quality, production, and metallurgy personnel. Every part produced is impacted by the expertise, tools, and focus of our engineering team. By applying best practice tools like PFMEA and control plans during the production process review, our team has successfully sustained a level of first-time through delivery and quality that exceeds customer expectations. After successfully delivering samples, engineering continually strives to reduce cost and improve quality through the use of Lean manufacturing and Six Sigma tools.

For an engineering consultation, call us today at 920-337-2470.

Specialty Capabilities

Manufacturing pressure vessels that operate safely in end-use applications is a big responsibility. For Calco to produce ASME ductile iron pressure vessels, structural integrity throughout the casting is paramount. This requires consistent processes and adherence to strict procedural requirements. Producing ASME ductile iron pressure vessels is a unique capability and one that is only shared with a few iron foundries in North America.

The American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, which specifies requirements for the design, manufacture, inspection and testing of pressure vessels, is the most recognized construction code. ASME is known globally and sets the standard for both the quality of products and the quality of manufacturers adhering to its procedures.

We are registered with the National Board for our production of ASME pressure vessels.

We’d love to hear about your company’s unique projects or challenges. Request a quote today!

Financing

 The C.A. Lawton Co., via its affiliate CALCO Finance LLC, will in select circumstances provide financing services.  When it’s the right thing for all parties in the value chain, financing will be utilized to facilitate the best outcome for all.  This may be tied to velocity or quantities or even quality.  Some situations that may prove relevant are tied to fixed assets (e.g. lease to own or installment purchase options on tooling or fixtures and similar items), where others are tied to working capital  (e.g. stocking & consignment programs and the like).  It could also be to assist a supplier-partner in their capability-related investments if that is the proper solution.

We are a manufacturing and engineering company, not a finance institution.  Thus the key concept here is providing solutions to get things done.   As with our sourcing programs (PFR), new product development (NPD) & material-type conversion initiatives, and the machining & other value added services for our castings, the goal is to provide a holistic and superior casting buying experience.   A properly set up and competently run financing arm is but another arrow in our quiver.