In foundry operations, even the smallest detail can mean the difference between a flawless pour and a costly production stoppage.
The story we’re about to share features an unlikely protagonist: engine-block spacers. This mechanical component plays a critical role, keeping the water-jacket core precisely in place during the casting process.
It’s a delicate operation because even a slight shift can lead to major issues during machining.
If a spacer isn’t perfectly centered, it can interfere with the cutting tool during cylinder machining, creating a significant risk of collision, tool damage, and expensive downtime.
Figure 1 – Spacer with central plate
The alert from the South African foundry: the spacer isn’t performing as intended
A South African–based foundry we’ve worked with for years contacted us about an emergency that was jeopardizing the entire production line: the spacers – custom-designed and manufactured by Vemek – were not performing as they should, resulting in significant casting defects.
To document the issue, the customer sent us two images showing an eroded and deformed spacer (Fig. 2) that was affecting the casting geometry. In a correctly controlled process (as shown in Fig. 3), the spacer’s cross-section remains perfectly straight, something that was clearly not happening in the case reported by the client.
Figure 2 – Casting cross-section with an eroded and deformed spacer
Figure 3 – Casting cross-section with a correct spacer
An intercontinental trip to deliver a rapid solution
At that point, there was only one thing to do: we booked the first flight to South Africa to tackle the issue on site and understand exactly what had happened.
This has always been a defining trait of Vemek (an approach we describe in detail in this article): we don’t position ourselves as simple suppliers, but as problem-solvers and trusted advisors, ready to provide prompt, specialized support (even if it takes a full day of travel). Our commitment goes beyond the product: we support the people who depend on it to work effectively, efficiently, and safely.
When on site, we encountered an unexpected development: the foundry had introduced a completely new pouring line. Every process parameter had changed. Our original custom support design had been engineered for an entirely different scenario; under the new process conditions, the casting defect was almost inevitable.
We started working immediately. Without losing time, we ran flow simulations to analyze the behavior of the molten iron. The results were clear: the new parameters were creating an abnormal flow pattern that struck the spacer area directly, progressively eroding it.
The solution: a new custom spacer, delivered in real time
Working closely with the foundry’s technicians, we immediately designed a double-stem solution capable of ensuring a smoother and more stable flow than the previous solid plate.
In just a few days – despite being roughly 12,000 kilometers from our operational headquarters – we set everything in motion thanks to exceptional coordination between the team on site and our engineers back home, who received the data and developed the new support accordingly. This allowed us to manufacture and ship the new samples in record time. On-site tests immediately confirmed that the issue had been resolved.
Since then, the South African foundry has been using this solution successfully, benefiting from long-term stability, durability, and consistently high quality.
Figure 4 – Spacer with two central stems
Vemek: the value of being there
This experience remains, for us, a tangible example of what true collaboration between client and supplier really means. It is an approach that sits at the core of our technical identity and the value we deliver every day. We are fully aware of how much our products can impact production and our clients’ plant uptime and throughput. For this reason, we never leave them on their own.
Responsiveness, technical expertise, and on-the-ground presence are the values that shape who we are and guide our actions. We believe that even in the most complex industrial environments, it’s the human factor that always makes the difference. That is how we see it at Vemek… and we are proud of it.