What is a sand reclamation system (Sandregeneration)?

A sand reclamation system, also called Sandregeneration, is the part of a foundry line that recovers used moulding sand from shakeout and returns it to the mixer for re-use. Modern closed-loop systems combine mechanical reclamation (crushing, scrubbing, attrition, screening, air classification) with thermal reclamation (calcining in a fluid-bed furnace) to remove binder residue and restore the sand to near-virgin quality. A well-designed plant routinely reclaims 90%+ of the sand, dramatically cutting raw-material cost and environmental impact.

What is the difference between mechanical and thermal sand reclamation?

Mechanical sand reclamation uses crushing, attrition and pneumatic or vibrating classification to break residual binder off the sand grains and remove fines. It is lower energy and lower cost, ideal for furan-based no-bake systems. Thermal sand reclamation uses a fluid-bed furnace at 600-800°C to burn off all organic binder residue, restoring the sand to near-virgin quality. Thermal is required for phenolic urethane and alkaline phenolic systems, and for the highest reclamation rates. Many Axmann plants combine both: mechanical as a primary stage, thermal as a secondary polishing stage.

What reclamation rate is achievable?

With mechanical reclamation alone, 70-85% of used sand can typically be returned to the mixer. Adding thermal reclamation as a secondary stage raises this to 90-95%+ depending on binder chemistry. Axmann designs the system around the target reclamation rate and the specific binder chemistry of the foundry, sizing mechanical and thermal stages accordingly.

How much does sand reclamation reduce my operating cost?

For a typical mid-sized no-bake foundry, moving from 0% reclamation to 90% reclamation cuts new-sand purchases by roughly 90% and sand disposal cost by 80-90% (some residual fines still leave the plant). Payback on a reclamation plant is usually 18-36 months depending on sand cost, landfill cost and production volume in the region. Axmann engineers a business case alongside every proposal.

Can Axmann retrofit reclamation into an existing no-bake line?

Yes. Axmann routinely retrofits mechanical and thermal sand reclamation into existing no-bake and chemically bonded sand lines. The retrofit is engineered around the existing shakeout, mixer and silo layout, with minimal production interruption. Axmann handles survey, engineering, fabrication, installation and commissioning end-to-end.

Sand Reclamation Systems: Mechanical & Thermal Sandregeneration | Closed-Loop Foundry Sand

Name: Sand Reclamation Systems (Sandregeneration)
Brand: AXMANN

A sand reclamation system, also called Sandregeneration, is the part of the foundry line that recovers used moulding sand from shakeout and returns it to the mixer for re-use. Modern closed-loop systems combine two stages: mechanical reclamation (crushing, scrubbing, attrition, screening, air classification) which breaks residual binder off the sand grains and removes fines, and thermal reclamation (calcining in a fluid-bed furnace at 600 to 800 °C) which burns off the last traces of organic binder and restores the sand close to virgin quality. A well-designed Axmann plant reclaims 90%+ of the sand per cycle, cutting raw-material cost and environmental footprint.

For a typical mid-sized no-bake foundry, installing reclamation cuts new-sand purchases by roughly 90%, reduces landfill tonnage by 80 to 90%, and typically pays back in 18 to 36 months. Axmann designs the mechanical and thermal stages around the specific binder chemistry (furan, phenolic urethane, alkaline phenolic), the target reclamation rate and the site layout. Retrofit into existing lines is routine.

1

Shakeout & Primary Separation

Vibrating shakeout separates the casting from the sand. Tramp metal, sprues and core residue are magnetically and pneumatically removed before the sand enters reclamation.

2

Crushing & Lump Breaking

Lump breakers and roll crushers reduce sand agglomerates to individual grains without fracturing the silica, the essential first step before attrition.

3

Mechanical Attrition & Scrubbing

Grains rub against each other at high intensity, mechanically fracturing the residual binder envelope without damaging the grain core. Fines are carried off by air.

4

Classification & Dedusting

Air classifiers and vibrating sieves separate reusable grain-size sand from fines, dust and over-size particles. Clean sand moves on; fines go to disposal.

5

Thermal Reclamation (Optional)

For 90%+ reclamation rates and for phenolic urethane or alkaline phenolic systems, sand passes through a fluid-bed calciner at 600 to 800 °C to burn off every trace of organic binder.

6

Cooling & Return to Silo

Reclaimed sand is cooled to mixer-inlet temperature, metered, and returned to the storage silo, closing the loop and feeding the next moulding cycle.

Mechanical reclamation plants

Thermal reclamation plants (fluid-bed calciners)

Shakeout units & casting separation

Lump breakers, crushers & scrubbers

Air classifiers, sieves & dedusting

Pneumatic conveying between stages

Sand cooling & return-to-silo systems

Retrofit into existing no-bake lines

Axmann foundry line with continuous mixer fed by reclaimed sand silo

Axmann sand preparation and reclamation plant, mechanical Sandregeneration

Axmann double-arm mixer using reclaimed sand in closed-loop foundry line

90%+ Sand Reuse

Well-designed mechanical+thermal plants reclaim 90 to 95% of used sand per cycle. The foundry stops being a sand consumer and becomes a sand recycler.

Lower New-Sand Cost

Virgin silica sand is a recurring cost. At 90% reclamation, the foundry's sand bill drops by roughly an order of magnitude, directly improving EBIT margin.

Lower Disposal & Landfill Cost

Foundry sand is classified as industrial waste in most jurisdictions, and landfill cost keeps rising. Reclamation removes that line from the operating budget.

Smaller Carbon Footprint

Virgin silica mining, transport and landfill disposal all carry CO₂. A closed-loop line cuts embodied carbon per tonne of good casting by 60 to 80%.

Consistent Sand Quality

Thermal reclamation restores sand close to virgin specification. Reclaimed quality becomes the spec, not a trade-off, consistent grain size, LOI and permeability.

Payback 18 to 36 Months

At typical European sand and landfill pricing, a mid-size reclamation plant pays itself back in under three years. Axmann engineers the business case with every proposal.

No-Bake & Chemically Bonded Sand Lines

Furan, Phenolic Urethane & Alphaset

Retrofit into Existing Foundries

Series Production & Large Castings

Mechanical Sand Reclamation

Primary reclamation stage: crushing, attrition, classification and dedusting. Ideal for furan-based no-bake systems.

Thermal Sand Reclamation

Fluid-bed calciner restores sand close to virgin spec. Required for phenolic urethane and alkaline phenolic systems, and for 90%+ reclamation.

Continuous Sand Mixers

Single-arm, double-arm and twin-shaft Durchlaufmischer. The mixer the reclamation plant feeds directly.

Ready to Close the Loop?

Your Sand Reclamation Plant, Engineered to Pay Back

Every reclamation project starts with a business case. Axmann sizes the mechanical and thermal stages around your binder chemistry, sand volume and target reclamation rate, and delivers a full cost-benefit model alongside the technical proposal.

New-build or retrofit, same engineering rigour, same German build quality, same end-to-end accountability.

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Sand Reclamation Systems:
Mechanical & Thermal Sandregeneration

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