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The U.S. and Canada, in certain respects, are the capital
of the die casting world. Perhaps this is because the high
pressure die casting process itself was invented in the early
years of the last century by Herman Doehler, and refined by
Doehler and others across North America. Today there are over
600 individual die casting plants operating in the two countries,
close to 20% of the world's total.
Together with Mexico, the third partner in the North American
Free Trade Area (NAFTA), the U.S. and Canada represent the
world's largest single market for die castings. In 2000, together
the U.S. and Canada shipped about 1.85 million metric tons
of pressure die castings. Right around two thirds of the total,
1.25 million tons, went for automotive uses. Other markets
include components for small gasoline engines used in lawn
and garden equipment, household appliances, electronics and
telecommunications.
Die casting in North America and elsewhere has received a
tremendous boost from the trend to lighter weight parts in
motor vehicles. The weight of aluminum in they typical family
car has risen from about 97 lbs. in 1977 to 245 lbs. as of
2000. Although other casting processes are used, pressure
die casitng has been the major beneficiary of this trend.
During the past decade or so, at least two other important
trends have become apparent, and continue to shape the industry
-- around the world, but perhaps most clearly in these two
countries. These trends include consolidations and globalization.
Large companies and investment groups have added to their
die casting holdings by acquiring smaller, stand-alone companies
as well as smaller company groups. And at the same time, larger
companies throughout North America have looked abroad for
expansion opportunities. Here are some examples:
J. L. French Automotive Die Castings Inc., with sales
in 2000 estimated to have exceeded $600 million. In addition
to plants in Sheboygan, WI, the headquarters, the company
operates plants in Michigan and Kentucky. Abroad, there are
three plants in the U.K., one in Spain, and one in Mexico,
all acquired since 1997. (More at www.jlfrench.com.)
Intermet Corporation, the well-known iron casting
company, is also believed to be the second largest die casting
company in North America. Holdings include the former Ganton
Technologies, with plants in Wisconsin, Michigan and Tennessee,
along with plants in Michigan and Minnesota. Intermet operates
a total of nine plants, including one in the U.K. As with
J. L. French, Intermet's business has grown through acquisitions.
(More at www.intermet.com.)
Gibbs Die Casting Aluminum Co., in contrast, has expanded
over the years into seven plants in Kentucky, along with one
on the U.S.-Mexico border in Harlingen, TX. In 1999 and 2000,
however, the company got into acquisitions in the form of
die casting plants in Korea and Brazil. (More at www.gibbsdc.com.)
Amcan Consolidated Technologies is a long-time Canadian
automotive die casting supplier. Amcan Operates plants in
Hamilton and Burlington, Ontario producing aluminum castings
and a magnesium die casting plant in Renfrew, Ontario. In
addition there is a plant in Brazil, Magal Foundry, in which
Amcan holds a 65% interest. The other 35% is held by Mercedes.
(More at www.amcancastings.com.)
Meridian Technologies is another Canadian company,
the largest producer of magnesium die castings in North America.
Their magnesium die casting plants are located at Strathroy,
Ontario and Eaton Rapids, MI. There is a third magnesium plant
in Italy as well. (More at www.mni.ca.)
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