Foundry Sand Technician

Role Overview

The Foundry Sand Technician is the technical guardian of our casting quality. This role is responsible for controlling, testing, and optimizing sand preparation and moulding processes across Cold Box, Alkaline Phenolic, and Green Sand systems. The ideal candidate does not just monitor machinery; they proactively analyse sand properties, adjust chemical parameters, and troubleshoot defects before they impact production. This position requires a meticulous, hands-on approach and a commitment to maintaining the highest standards of technical accuracy and operational safety.

Key Responsibilities

Process Control & Optimization

• Green Sand Systems: Monitor and adjust moisture, clay content (active clay), compactability, permeability, and green compression strength to ensure optimal mould integrity.
• Cold Box Systems: Oversee resin and catalyst (amine gas) dosing, ensuring accurate mixing ratios for core strength and minimizing gas defects.
• Alkaline Phenolic Systems: Manage the ester-cured resin systems, controlling setting times, bench life, and strip times based on ambient conditions and casting requirements.
• Continuously monitor muller and mixer performance, adjusting calibration to maintain consistent sand quality across all lines.

Quality Assurance & Laboratory Testing

• Conduct daily and hourly sand laboratory tests (e.g., Loss on Ignition (LOI), AFS grain fineness, tensile strength, scratch hardness, and moisture analysis).
• Record and analyse test data to identify trends, establishing statistical process controls to prevent sand-related casting defects (such as porosity, scabs, blowholes, or sand inclusions).
• Quarantine and reject out-of-spec sand batches, implementing immediate corrective actions.

Troubleshooting & Continuous Improvement

• Act as the primary technical responder for the moulding lines and core shop when sand-related issues arise.
• Collaborate with metallurgists, methoding engineers, and production supervisors to investigate scrap castings and refine sand formulations.
• Champion continuous improvement initiatives to reduce sand consumption, optimize binder usage, and improve sand reclamation efficiency.

Maintenance & Compliance

• Perform routine calibration and basic preventative maintenance on sand testing equipment and chemical dosing pumps.
• Ensure all sand preparation and testing activities strictly adhere to integrated management systems, maintaining total audit readiness for ISO 9001 (Quality), ISO 14001 (Environmental), and ISO 45001 (Health & Safety) standards.
• Maintain a clean, organized, and safe laboratory and work environment.

The Ideal Candidate Profile ("A-Player" Traits)

• Technically Exacting: You possess a deep respect for precision. You understand that a 0.5% variance in moisture or resin can compromise an entire casting run.
• Proactive Problem Solver: You do not wait for scrap to tell you something is wrong. You read the sand data and adjust parameters pre-emptively.
• Accountable: You take full ownership of the sand plant's output and are comfortable making the call to halt production if quality standards are not met.
• Collaborative Communicator: You can explain complex technical variations to production operators clearly and effectively without relying on jargon, fostering a team-oriented environment.

Minimum Qualifications & Experience

• Education: Matric (Not Negotiable)

National Diploma in Metallurgy, Foundry Technology, or a relevant technical trade qualification (e.g., specialized foundry artisan/technician). (Preferred)

• Experience: Minimum of 3–5 years of direct, hands-on experience in a foundry sand laboratory or sand plant.
• Specialized Knowledge: Proven, demonstrable expertise in operating and troubleshooting Cold Box, Alkaline Phenolic, and Green Sand systems.
• Systems: Familiarity with continuous mixers, core shooters, automatic green sand moulding lines, and standard foundry laboratory testing equipment.
• Computer Literacy: Proficient in data entry and analysis tools (e.g., Excel, ERP systems) for tracking quality metrics.

Working Conditions & Additional Requirements

• Transport: Must possess a valid driver’s license and own a reliable vehicle, as the role requires independent travel and the ability to respond to potential callouts.
• Operational Flexibility: While standard hours apply, the candidate must be willing and able to work overtime, including occasional weekends or shift extensions, to support critical production runs, maintenance windows, or urgent troubleshooting.
• Environment: Comfortable working in a heavy industrial foundry setting, which involves exposure to heat, noise, and chemical binders, while strictly adhering to all safety and protective protocols.

Pay: R7 327,22 - R28 881,30 per month

Work Location: In person