The fact that BIRN in Holstebro is now one of the largest and most flexible iron foundries in the Nordic region is largely due to a collaboration that goes back more than 50 years. Since 1972, BIRN and the industrial company DISA have developed, tested and refined casting technology together – a partnership that has left a lasting mark on both companies and which is receiving special attention this year in connection with DISA's 125th anniversary.
Since the first DISAMATIC machine was installed at BIRN in 1972, DISA technology has been an integral part of everyday life in Holstebro. The combination of modern machines, practical experience and ongoing sparring has helped shape a production that handles thousands of castings every week – often in complex series, many weight classes and a wide range of alloys.
- A DISAMATIC machine is basically a fully automatic system that produces precise sand moulds at high speed. This gives us a very stable and efficient casting process, and it is one of the reasons why we can handle so many different items in so many series sizes. The technology is central to how we run our foundry, says Lars Jørgensen.
Over the years, the collaboration has given BIRN the opportunity to test new solutions on a full scale, optimise processes and improve quality – while also contributing to the development of new generations of DISA machines. It is a collaboration that has strengthened both the flexibility and competitiveness of BIRN's production in practice, and which remains an important part of the foundation of the foundry's daily operations.
The fact that DISA is celebrating its 125th anniversary this year only highlights the solid history on which the collaboration between the two companies is based.
From the first DISA machine to five advanced moulding lines
The first DISAMATIC machine in 1972 marked the start of a collaboration that has grown in both scope and significance over the years.
Today, BIRN has five DISA lines in four different models – DISA 230, 240, 270 and 2070 – and the combination of technologies provides a flexibility that, according to Production Director Lars Jørgensen, is absolutely crucial:
- We have never been afraid of equipment at BIRN. As a result, we now have a broad portfolio of machines that give us clear advantages in the market. DISA technology enables us to produce everything from small series to complex items in many different weight classes and alloys. This is an important part of our DNA as a flexible foundry, says Lars Jørgensen, Production Director at BIRN.
A development partnership with mutual value
DISA has a small test foundry for testing new castings and alloys, while larger and full-scale production is carried out in collaboration with BIRN. Here, new technologies, machine improvements and production methods are tested on a full scale – often in close collaboration with BIRN's employees.
- BIRN is more than just a customer to us. They are a development partner with whom we have worked closely for decades. Their production environment and technical insight mean that we can test new solutions in practice – and when they work at BIRN, we know that they work in reality, says Ulla Tønnesen, President at DISA.
The close relationship is also evident when DISA regularly takes customers on tours of Holstebro to show their machines in full operation. BIRN often serves as a reference case, and the collaboration is characterised by great mutual respect.
Production based on technology, know-how and flexibility
BIRN produces around 1,000 different unique items annually and has approximately 2,000 active items in its portfolio. This is only possible because the company has built up a deep understanding of DISAMATIC technology – and because flexibility is a strategic priority.
Over the years, BIRN employees have contributed ideas, suggestions and adjustments that have subsequently been implemented in DISA's machines. It is a collaboration where practical experience and technological development go hand in hand.
- When we work with DISA, we share a common understanding that nothing is impossible. It's about perseverance and finding the solutions that create the best possible quality and stability in the casting process. Several of the improvements we use today were born out of sparring between our technical teams, says Lars Jørgensen.
As DISA celebrates its 125th anniversary, its relationship with BIRN remains one of the longest-standing and most valuable collaborations in the history of both companies. And everything indicates that this development will continue.
- We have been working together for more than five decades, and we will continue to do so because we are better together. The collaboration with DISA has helped shape our production over many years, and it continues to be an important partner in the development we are facing, concludes Lars Jørgensen.
An idea that began in Holstebro
The collaboration between BIRN and DISA is not only based on five decades of joint development – it also has historical roots in Holstebro. The idea that later became the world-leading DISAMATIC technology originated with Vagn Aage Jeppesen, who was an apprentice at Vald. Birns Jernstøberi & Maskinfabrik A/S from 1934 to 1938. After his apprenticeship, he trained as a mechanical engineer and developed the basic principle that was later further developed under Dansk Industrisyndikat A/S and formed the basis for the DISAMATIC automatic moulding machine.
The fact that one of the foundry industry's most important technologies can be traced back to an employee at BIRN in Holstebro only emphasises the long-standing ties between the two companies – and why the collaboration is still going strong today.