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reducing foundry downtime through digital sand monitoring

smart manufacturing in Pageland, South Carolina

At Aalberts integrated piping systems, operational excellence is built on innovation, data, and decades of manufacturing expertise. Across three South Carolina facilities, including two in Pageland, our teams continue to invest in advanced technologies that drive efficiency, reliability, and long-term performance.

At our Pageland operations, including the Bypass foundry facility established in March 1998, we recently implemented a digital foundry solution that has transformed how we monitor and manage sand processes, resulting in a reduction in sand-related down time.

the challenge: limited visibility in foundry sand processes

Like many foundries, our sand systems are critical to maintaining production flow and casting quality. Historically, sand data was fragmented across multiple systems and required manual compilation—limiting real-time decision-making and increasing the risk of downtime.

This created a key operational challenge:

  • Delays caused by “waiting on sand”
  • Reactive maintenance instead of proactive control
  • Time-intensive reporting processes

the solution: real-time foundry data with Monitizer®

To address this, Aalberts implemented the Monitizer® | DISCOVER IIoT platform across its Pageland foundry operations.

This digital solution connects directly to existing equipment, providing:

  • Real-time sand quality monitoring
  • Centralized process data dashboards
  • Automated reporting and analytics
  • Improved process visibility across teams

The implementation was completed in a matter of weeks, with minimal disruption to ongoing operations.

the results: large reduction in downtime

With real-time visibility into sand conditions, our teams can now identify and resolve issues before they impact production.

Key outcomes include:

  • Improved labor efficiency and production throughput
  • Elimination of manual data collection and reporting
  • Faster, more informed operational decisions
Reducing Downtime with Digital Sand Monitoring

“Operational excellence depends on timely, accurate information. With real-time sand data, our teams can identify issues early, correct them immediately, and keep production moving without interruption.” — Héctor González, COO, Aalberts IPS Americas.

key products supported through this process

built on legacy, driven by innovation

Our Pageland operations are more than just production facilities, they are a foundation of American manufacturing excellence.

The Bypass foundry, operating since 1998, represents decades of expertise in brass casting and valve manufacturing. Today, that legacy is enhanced through digital transformation, combining proven manufacturing processes with modern IIoT technology.

This scalable approach allows us to connect both legacy and modern equipment into a unified platform, building a smarter, more responsive manufacturing environment.

“When our teams have clear, real-time insight into their processes, they can make better decisions, move faster, and run the business more effectively.” — Jacob Speight, CEO, Aalberts IPS Americas

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PUBLICITY WAIVER AND RELEASE

Aalberts integrated piping systems Americas, Inc., a North Carolina corporation with offices located at 10715 Sikes Place, Suite 200, Charlotte, North Carolina (the “Company“), desires to use and publicize the name, likeness, and other personal characteristics and private information of the individual named below with a residence at the address set out below (“I” or “me“) for advertising, promotion, and other commercial and business purposes. In exchange for the intangible value I will gain by participating in Company’s publicity programs/a one-time payment in the amount of $0 and other good and valuable consideration, the receipt and sufficiency of which I hereby acknowledge, I give Company my permission for such use and publicity for such purposes, according to the terms and conditions set forth in this Publicity Waiver and Release (“Agreement“).

 I hereby irrevocably permit, authorize, grant, and license Company and its affiliates, successors, and assigns, [and their respective licensees, advertising agencies, promotion agencies, and fulfillment agencies,] and the employees, officers, directors, and agents of each and all of them (“Authorized Persons“), the rights to display, publicly perform, exhibit, transmit, broadcast, reproduce, record, photograph, digitize, modify, alter, edit, adapt, create derivative works, exploit, sell, rent, license, otherwise use, and permit others to use my name, image, likeness, and appearance, voice, professional and personal biographical information, signature and other personal characteristics and private information, and all materials created by or on behalf of Company that incorporate any of the foregoing (“Materials“) in perpetuity throughout the universe in any medium or format whatsoever now existing or hereafter created, including but not limited to, in and on magazines, brochures and other print publications, electronic, magnetic, and optical media, motion pictures, television broadcast, cablecast, and satellite, home video and video on demand, radio broadcasts, display, point-of-sale, and other advertising and promotional materials, press releases, the internet and other digital transmission or delivery methods, mobile applications, on any platform and for any purpose, including but not limited to advertising, public relations, publicity, packaging, and promotion of Company and its affiliates and their businesses, products, and services, without further consent from or royalty, payment, or other compensation to me.

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