By Bernard Martin

For almost a century, the Hall family has been at the forefront of the iron casting industry. Starting in the 1920s with Alfred J. "AJ" Hall, and continuing with his son, Alfred B. "Fritz" Hall, who became president of Benton Foundry in 1975, transforming it from a modest operation pouring 22 tons of iron daily into a visionary enterprise. By 1990, under Fritz's son Jeff, the foundry's capacity increased to 80 tons per day.

Benton Foundry has consistently reinvested profits into capital improvements, now operating a state-of-the-art facility with a capacity of 175 tons per day, aiming for 250. Unlike other foundries, Benton has prioritized core room expansion and strategic planning over short-term gains, contributing to its unbroken record of financial growth since 1975.

Back in 2002 Laurie Barcaskey at Leading Marks developed the precursor to the today's Boss Buddy as an application solution at Benton Foundary. Traditional embossing, as was being done at Benton, required a male and female die to create the embossed effect on thin gauge materials, often resulting in tearing of the material and inconsistent quality. 

Fast forward to 2014 and Laurie ran into a similar application problem as the one that she had solved over a decade prior at Benton.  And that began the official creation of the Boss Buddy. The inception of the Boss Buddy stemmed from a need to overcome the challenges that Benton had experienced, and dictated introducing a new method that utilizes a female urethane mating piece instead of both dies. This innovative approach not only reduced material waste but also ensured a more consistent quality of embossed characters on metal tapes, such as the foil or stainless tapes available for use with the today's Boss Buddy.

Unlike the typical wheel system that embosses one character at a time, today's Boss Buddy employs impact presses that emboss a complete set of characters at once. This method allows for the inclusion of custom characters and longer numbers, offering a solution that is both faster and more consistent. The Boss Buddy's adaptability extends to accommodating different types of metal tapes, catering to a wider range of industry needs.

Laurie's expertise in the marking industry played a crucial role in the development of the Boss Buddy, a manual system designed to emboss foil labels used commonly for pattern ID. This system addresses the industry's challenges head-on, providing a solution that leverages traditional components to replace outdated technology. The automation aspect of the Boss Buddy Plus signifies a notable advancement in the foundry sector, where efficiency and reliability are paramount.

The continuing story of the Boss Buddy is also one of collaboration and technical support. In the fall of 2023, Jason Karcher of Benton Foundry reached out to Laurie for assistance with the some of the components on the original design solution at their plant that was not functioning optimally. Actually, it's quite a testament to a design that had been in constant service for 20 years.  

According to Jason Karcher, Tooling Department Manager at Benton Foundry, "There are few options for applying traceability for certified parts so it's essential that this unit remains operational for our process and pattern labeling. The unit was not operating correctly and some band-aids were used until Laurie visited and discussed the replacement parts and shared schematics."

Laurie proposed to replace some press parts and introduce new steel type characters, along with arranging for a spare energy section for hot swaps, exemplifies the ongoing commitment to streamlining maintenance allowing a quick return to operation and customer service at Leading Marks.

Karcher continues the story. "When the parts arrived, the unit was put back into first-class operation very quickly. It was a simple repair. I spent some time pulling the machine apart. Replaced the items that have worn over the 20-ish years in service. Surprisingly it wasn’t in all that bad shape. The replacement parts fit as expected! The Machine runs well. More importantly I have a greater peace of mind knowing I have replacement parts in house in the event something breaks."

"All-in-all the process of ordering, replacing, and stocking the replacement parts/springs & do-dads went very well. I really appreciate Laurie's advice and help on this machine. Her years of knowledge and experience are unmatched. I expect it to run problem free in the back ground for some time." said Karcher.

The Boss Buddy's exemplifies how addressing specific challenges through innovation can lead to advancements that benefit the entire sector. Benton Foundry's history, marked by consistent growth and strategic investments, provides the perfect backdrop for the development of such a transformative solution. The Boss Buddy is not just a product; it's a symbol of progress in the foundry industry, showcasing how traditional processes can be reimagined for greater efficiency and reliability.
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As the foundry sector continues to evolve, the Boss Buddy stands as a prime example of how innovative solutions can drive industry-wide change. Its development process, from conception to implementation, underscores the importance of expertise, collaboration, and a deep understanding of industry challenges. The success of the Boss Buddy and its impact on Benton Foundry's operations highlight the potential for similar innovations to shape the future of manufacturing and industrial processes, ensuring sustainability and growth in an ever-changing technological landscape.

Benton Foundry, nestled within 200 acres of Pennsylvania's scenic landscape, has been recognized as the "Metalcaster of the Year" by Modern Casting magazine for its significant coremaking expansion. ​​This recent project, completing 70,000 sq. ft. of new and renovated space in fall 2022, has notably enhanced the foundry's capacity, efficiency, and job creation.

​The expansion reflects Benton's long-standing philosophy of reinvestment and modernization, a practice initiated by Fritz Hall in the 1970s and continued today under the leadership of his son, Jeff Hall, the current president.

The Metalcasting Congress attracts attendees from across the foundry industry, as well as professionals from other businesses within the manufacturing supply chain.

​Nestled along Lake Erie’s southern shore, Cleveland is the second largest city in Ohio.  Huntington Convention Center of Cleveland is hosting Metalcasting Congress 2023, providing over 410,000 square feet of prime meeting and event space. The convention center is also just 25 minutes away from Cleveland Hopkins International Airport.

Leading Marks will be demonstrating the latest in part marking and identification technology.  ​ ​We will be featuring The Boss Buddy embossing system offering improved efficiency and improved legibility for pattern labeling.  ​

See the latest trends in smart manufacturing! The newest equipment for your plant! The best in research and expertise. Get a head start on the competition by exploring tomorrow’s metalcasting advancements today. The Metalcasting Congress attracts attendees from across the foundry industry, as well as professionals from other businesses within the manufacturing supply chain.

Leading Marks will be previewing improved efficiency and improved legibility for pattern labeling with the Boss Buddy embossing system, as well as secondary marking requirements with direct-part marking systems, dot peen, laser & stamps, ink marking, hand-held & automated systems and thermal transfer labeling solutions. Additional product solutions offered include: workbenches, air filtration, vision, handheld scanners and in-line options, soldering irons, machining accessories and more.

Leading Marks will be demonstrating the following products in our booth #715

This article about the Boss Buddy application at ITT Gould Pumps originally appeared in Modern Casting. We are republishing it now to coincide with the introduction of our new Boss Buddy Catalog.  Be sure to grab a copy to download here on our Boss Buddy page! 

Therefore, Lucas set out to find a more effective solution to support the organization. Lucas took the initiative to identify the foundry marking requirements before looking for new equipment. He determined that an effective solution must include:

• The ability to mark multiple char- acter sizes.
• Fast creation of repetitive legends.
• Material that was viable for the
  process.
• Something that fit the budget.

An article in Modern Casting describing the Leading Marks tagging system caught Lucas’ interest.
“We had been struggling with tagging legibility issues for years,” he said. “With our 3D printer, I had been adjusting and proving out a font and tag sizes. I printed thousands of tags, over the course of a year.”

He saw that the Boss Buddy embosses foil tape for use in foundry applications such as pattern labeling, and read that the Boss Buddy is compact, simple to operate, cost-effective and uses proven components customized for foundry requirements.

Leading Marks had been working with many foundries around the U.S. to improve their processes. After 
working with Leading Marks to test date code samples in a couple of character sizes, Lucas said he obtained much more legible marks that were created in less than half the time of the older system and with far greater ease. With favorable results in hand, they began defining what the package should include: Interchangeable type characters in the custom font that Lucas had designed. Characters in a variety of sizes Manual Boss Buddy embossing system (vs. the automated system).

The Boss Buddy system shipped to the facility in Seneca Falls, New York in the spring of 2019. After Lucas’ preliminary use of the Boss Buddy package in the pattern shop, it moved to the shop floor.

Ryan Knapp, molding supervisor at ITT Goulds Pumps uses it daily, quick- ly creating the pattern labels needed by the foundry. During a follow-up meeting with Laurie Barcaskey from Leading Marks, Knapp created even more clearly defined embossed characters with a simple change in the spring used in the impact press. Knapp is relieved he no longer must use the old system, aka the “Spin to Win” for pattern labels. Knapp will be championing the efforts of other departments to employ this solution throughout the plant.

​When asked about the implemen- tation of the new system. Lucas said “I was pleasantly surprised that Leading Marks did not flinch when I men- tioned creating dies for the font I had been 3D printing.”
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“Leading Marks had some great ideas on implementing the tagging project. Prior to seeing the Modern Casting piece, I was going in a different direction. It saved a lot of time going with proven equipment and a knowledgeable vendor.”

Leading Marks can help you with traceability from the shop floor where machine to machine communication and data-collection is crucial to mobilizing reporting from the warehouse or in the field.

Traceability is common for collection, look-up and sharing of data. Whether it is Asset Tracking, EH&S Inspections, QA/QC Controls, Work-in-process, Assembly builds, or Field Service reporting industry is driving the need for traceability from cradle to grave. Why is traceability important for your organization?

What’s the value-add with the potential of data collected through mobile apps or plant-floor software packages?

• Auto-trigger of reports and work orders based on data collected
• Quicker reporting
• Query and filter of data
• Minimize down-time on the production line or field operation
• Trends & variations evaluation

Looking Ahead to 2021 we are excited about the solutions our vendor partners are providing to manufacturing operations, construction projects and food processing requirements. Whether your needs are for marking or the related equipment Leading Marks is prepared to help evaluate your applications with sample marks with the various technologies.

We strive to better understand your requirements based on the industry specifications, product and/or substrates to be marked, the environment it is subject to, available budget and other expectations that apply.

To better acquaint you to the product solutions and the limited ability to visit during these continued uncharted times, we are preparing a schedule of webinars with our vendors. If you want to be alerted to the workshops, please email [email protected].

Exciting things are in store in 2021 as Leading Marks continues to Identify Solutions to suit your needs.Happy New Year!

When people ask me what I do to earn a living and respond that I sell industrial identification systems, aka marking,  people often give me a puzzled look and ask “What is that?”

Their enthusiasm to plan and build something and then compete with other high schools at the annual Bots Tournament in southwestern PA is exciting and fun.

​The mechanical and life skills the students gain is critical to setting them up for success as they look for jobs, attend trade school, or seek degrees.  The suppliers and manufacturers who support them gain direct insight to future employees and the local educational systems and networking opportunities with other professionals. It is a win-win for everyone.

Becoming Women Business Enterprise (WBE) certified opens the doors to opportunities with government and large corporations who value diverse suppliers. This certification also enables me to encourage young women involved in the SW Bots program or just starting their careers within manufacturing and construction. While these industries are inviting more women to be a part of their organizations, there are still many more efforts needed to diversify and level the playing field.

Now that you know all of this about me and a bit of the background of Leading Marks, what is the solution we can help you with?

Check out the full length version of this story  “Impacting the Pattern Labeling Process Marking System Increases Efficiency.” at the bottom of the article.

A shorter version of this article will also be published by Modern Casting under the title “Marking System Increases Efficiency” in their February 2020 issue.

This article presents the story of how the Boss Buddy provides a cost effective, easy-to-use solution to the pattern marking issues that many foundries and manufacturers are facing. It is a case study of Leading Mark’s partnership with Goulds Pumps; the article talks about

• The state of pattern marking
• Gould’s search for a solution
• the implementation of the Boss Buddy

​As many in the foundry  industry know, not only is older marking equipment being phased out; many companies are looking pattern making systems that create more legible and faster labels.  Pattern marking is critical since it provides a mechanism for process control and quality Tracking.  Tracking piece quality throughout the process allows companies to track operations and limit batch size is issues arise.  The Boss Buddy embosses foil tape, is compact, and uses proven components customized to meet foundry requirements.

Leading Marks  was planning to exhibit at AFS’ Medtalcasting Congress at the end of April in Cleveland Ohio.  Due to the COVID-19 pandemic, the show has been cancelled. ​

PITTSBURGH, PA.   Leading Marks LLC is excited to announces a package for foundary pattern labeling that improves legibility for cast-in identification, and provides cost savings through labor and material costs. A marking press and a custom designed accessory package impact legends in one stroke of the press rather than rotating wheels one character at a time.

The core of the package that hammers in the legends is a spring-loaded impact press. These units are proven marking devices with low-maintenance requirements. While manual systems are most common for replacing traditional pattern labeling devices with single character wheels, semi-automated systems are available for high-volume labeling requirements.

A steel type arrangement embosses the characters into foil tape. The male type is mounted in a steel chase, nested on a manual feed assembly. Included in the feed assembly is a spool feed for the material, friction rollers, and a manual knob for advancing the material.  Automated systems included more advanced material feed arrangement.

Three standard chases accommodate a range of character sizes. Chase assemblies can be interchanged to accommodate a wider range of sizes and tape guide arrangements.

Character sizes range from 1/8” up to 3/4″ high. Standard alphanumeric characters, as well as symbols and logo are available and quoted upon request.

The accessory package is designed to accommodate three standard tape widths; 13/32”, 5/8” and 7/8”. The 5-mil aluminum tape comes with rugged adhesive that is more pliable on curved surfaces than plastic tapes common to the pattern labeling process.

Leading Marks is a proven supplier for marking and traceability requirements. Our product line includes a variety of direct-part marking systems, manual and electronic ink marking devices, thermal transfer label printers, preprinted labels, nameplates and other bar coded devices. A mobile app completes the traceability requirements for industry with data-collection, work-flow engine triggers, and reporting accessory package.