Foundry Chemicals - Foundry Binders

Foundry Binders

IVP presents a varied range of resin solutions, designed to meet the unique requirements of our customers. Our formulations offer customised innovations and flexibility of use.


Shell Resin is a novolac, specifically a thermoplastic phenol-formaldehyde resin. This binder system is utilised to produce resin-coated sand, a crucial component in foundries for crafting cores and molds. Resin-coated sand enables the creation of castings with highly precise dimensions and smooth surfaces. It finds applications in the production of cores and molds for both ferrous and non-ferrous metal casting, catering to various industries such as automobile foundries, pump and motor casting foundries, engine block foundries, and other general engineering sectors. Additionally, epoxy-modified grades are available, enhancing the cold strength (both transverse and tensile) of resin-coated sand. These modified grades are particularly well-suited for thin-section shell cores, including water jackets.

A no-bake foundry binder system, the 2-Part Acid-Cured No-Bake System employs resole phenol-formaldehyde chemistry. Designed to enhance the foundry environment, this two-part resin system facilitates the production of superior quality castings. It is well-suited for the casting of iron, steel, and steel alloys. Its versatility extends to floor molding, as well as high-speed loop and carousel operations. Notably, it boasts negligible nitrogen content.

The 2-Part Alkaline No-Bake System comprises a phenolic resole resin with a highly alkaline nature, featuring very low free formaldehyde and low free phenol. Cured by an organic ester or a blend of esters, this water-soluble resin system is designed for the production of enhanced quality castings. Notably, it significantly reduces expansion defects inherent to steel metallurgy. On stainless and alloyed steel, the system minimises surface carbon pickup. Moreover, it offers specific advantages to aluminium and magnesium castings, resulting in improved shakeout and reduced or eliminated staining. Noteworthy improvements include a reduction in shakeout times for cores and molds by up to 50-90%.

The Alkyd Resin range constitutes a three-part system comprising a resin (Part A), a catalyst (Part B), and a hardener (Part C). The resin is a thermoplastic polyester resin created by heating standard vegetable oils with polybasic acids or their anhydrides. The catalyst is a mixture of metal octoates, while the hardener is MDI (methylene diphenyl diisocyanate). This versatile system is suitable for both small and large cores and molds, accommodating ferrous and non-ferrous castings.

The Phenolic Urethane Cold Box (PUCB) process employs an amine gas to catalyze the reaction between a phenolic resin and an isocyanate, resulting in the formation of a urethane bond. The resin components, both Part 1 and Part 2, are combined with appropriate sand during the mixing process.The resulting sand mix is then blown into a core box and cross-linked by the passage of vaporized tertiary amine catalyst, producing a urethane bond. Curing occurs uniformly and consistently. Primarily utilized in the casting of cores for automotive applications due to its outstanding dimensional accuracy, the cold box process is also suitable for iron castings. It proves efficient for high productivity and is particularly advantageous for the production of large cores requiring rapid strength increase.

The Furan No-Bake System is a two-part system comprising a resin in furfuryl alcohol, cured by an acid catalyst. A 'No-Nitrogen' Grade is available in this resin. The absence of nitrogen in this system yields notable benefits, especially in steel castings, resulting in a significant improvement in casting quality and reduced cleaning room costs. It is recommended for the production of cores and molds for both iron and critical steel castings. The furan system proves particularly useful when incorporating high amounts of reclaimed sand, where the resin requirement is substantially lower.

The No-Bake Phenolic Resin system is a three-part system known for its rapid through-curing Phenolic Urethane System, making it ideal for crafting medium and large cores and molds with a repetitive nature. It stands out as the fastest among all other No-Bake systems. This versatile system is suitable for both ferrous and non-ferrous casting production. With its high tensile strength and erosion resistance to metal, it ensures the precise dimensions of castings are maintained, resulting in sound castings.

The CO2 Cured Resin is a water-soluble alkaline phenolic resin cured by carbon dioxide. The single resin component is mixed with sand, blown into a core/mold box, and cured by the passage of carbon dioxide gas through the sand. This system is distinguished by its lack of obnoxious smell during mixing. It is a non-flammable, water-based system that does not require gas scrubbing.