Ferralloy, Inc. supplies high-quality machined castings and forgings that are compatible with processes and sanitation requirements in the food and beverage industry. We work with a variety of heat- and corrosion-resistant metals that are widely used in food processing equipment for mixing, milling, filling, conveyance, and more.

Learn more about our capabilities and how the parts we make are used in food and beverage applications.

Ferralloy’s Capabilities and Materials for Food Processing Components

Ferralloy specializes in forging, casting, and machining processes that result in durable, precision parts that are up to the challenges of food and beverage processing and production.

Forgings

Forging is the process of shaping a metal workpiece by first heating it until it is malleable, then hammering or otherwise applying force to it, which deforms it and creates the desired shape. Our capabilities include different types of forging operations:

  • Open die. The workpiece is not formed in a mold for shaping, rather it is struck or hammered into the desired shape. This process improves fatigue resistance and strength and is a good choice for large and/or custom pieces.
  • Closed die. The material is heated in a furnace for malleability, then placed between the two portions of a custom-sized die and pressed into shape, filling the die cavity under high pressure. This is a precision process that can produce a near-net shape with consistent features and with minimum material waste.
  • Ring rolling. This process creates a round, flat ring-shaped component with a consistent grain structure. A solid billet or workpiece is heated, pressed flat and then pierced in the center and supported by a mandrel on the rolling mill. The outer diameter of the piece is pressed against a roller as the piece is turned to form the shape. An axial roller is also used to adjust the thickness of the piece.

Forging is compatible with many types of metal, including stainless and carbon steels as well as high-performance alloys.

Castings

In casting processes a negative mold or ‘pattern’ of the part is created, then the void is filled with molten metal. Cast parts are seamless and have low porosity, which provides fewer surfaces and crevices for bacteria or particles to collect, making cleaning and sanitizing more efficient and effective. Casting is also a good choice for producing geometrically complex parts, with consistency from one part to another.

Our food and beverage component casting operations include:

  • Investment/Lost wax. Molten wax is injected into a metal die, cooled, and extracted. The wax mold then undergoes the shelling process, where multiple layers of ceramics are applied to the outside of the mold. Once the mold is set, it is heated to allow the wax to melt away, then the molten metal is gravity fed or vacuum poured into the mold. Multiple molds can be poured at the same time, yielding a high number of castings from each pour.
  • Centrifugal. This process is well-suited to cylindrical tubes and other hollow, round forms. The material is poured into a rotating mold, and the centrifugal force pushes the material outward, filling the mold completely.

Stainless steel is a common material for these processes; however, they are also compatible with other steels, aluminum, nickel alloys, and various superalloys.

Stainless Steel Alloys and Superalloys for Food and Beverage Applications

Corrosion resistant alloys and stainless steels are widely used for food and beverage equipment for processes such as filtration & separation, rollers, mixing, filling, shafts, conveyance lines and fittings. The best material option depends on the process application, temperature, corrosion resistance, and chemicals the parts will be exposed to. We work with a variety of superalloys, stainless steel grades, and other metals. Some common examples include, but are not limited to:

  • Stainless steel grades 304 and 316: Widely used for their resistance to acids, bases, salt, and dairy foods and are suitable for forging or casting processes.
  • 400 series stainless steel: Often used in high-temperature applications and when wear resistance is needed, and these components are frequently cast.
  • AL 6XN: Stainless steel grade that also contains molybdenum, nickel, and chromium and is resistant to pitting.
  • Duplex 2205: High-strength and corrosion-resistant.
  • Hastelloy: A superalloy series made with nickel, chromium, and molybdenum; excellent corrosion resistance and dimensional stability in high temperatures.
  • Inconel: A series of superalloys with excellent corrosion-, oxidation-, and temperature-resistance in heavy-duty applications; nonreactive and easy to clean.

Common Applications for Forged and Cast Parts in Food & Beverage Equipment

Because they offer exceptional strength and provide easy to clean surface finishes that are sanitary and resistant to bacteria and mold growth, stainless steel forgings and castings are commonly used for food and beverage industry equipment. Examples include:

  • Components for milling and mixing equipment.
  • Flanges and fittings.
  • Gears and roller parts for conveyors.
  • Parts for automated machinery and bottling lines.
  • Shafts for grinders, augers, and crushers.
  • Mixer blades.

Contact Ferralloy for Food and Beverage Grade Forged and Cast Components

As a global leader in custom metal products, Ferralloy, is an experienced supplier of high-quality cast, forged, and machined components, made from sanitary grade stainless steel and alloys. We offer inventory stocking for just in time delivery, engineering support and expertise in selecting the proper alloy for your application.. We offer solutions for your metal product needs.

Contact us to learn more about the advantages of forging and casting for food industry parts and equipment, or request a quote to start your order!