exothermic feeder sleeve manufacturers-TURKEY
GES DOKUM | Company Profile
GES Foundry Products and Metallurgy (GES Dokum) is a leading Turkish manufacturer specializing in the production of advanced foundry consumables for the iron, steel, and metal casting industries. Established in 2004, the company has accumulated over 30 years of combined industry experience and has grown to become one of the two most prominent companies in the foundry consumables sector in Turkey. Operating from a state-of-the-art production facility located near the Duzce 1st Organized Industrial Zone, GES Dokum serves both domestic and international markets with a comprehensive product portfolio that includes mini risers, exothermic feeder sleeves, cover powders, and shell and metal breakers.
The company's manufacturing facility spans a total area of 12,000 square meters, encompassing both indoor and outdoor production areas as well as administrative buildings. Since relocating to its modern production site in 2014, GES Dokum has achieved an impressive annual production capacity of 12,000,000 units, enabling it to meet the growing demands of foundries across the Americas, Europe, Asia, and the Middle East. The company holds ISO 9001:2008 and OHSAS 18001:2007 quality management certifications, reflecting its unwavering commitment to manufacturing excellence and workplace safety standards.
Table of Contents
1. Company Overview
GES Foundry Products and Metallurgy Company was established with the vision of becoming a reliable and innovative supplier of foundry consumables to the global metal casting industry. Over the past two decades, the company has built a reputation for producing high-performance products that enhance the quality and efficiency of iron and steel casting processes. The company's headquarters and primary manufacturing facility are situated at Istiklal Mahallesi, 12. Cadde No: 12, 81600 Beykoy, Duzce, Turkey, strategically located within proximity to the Duzce 1st Organized Industrial Site.
GES Dokum's product line was developed to address critical challenges faced by foundries worldwide, particularly in the areas of shrinkage prevention, thermal insulation, and efficient feeding during the casting process. The company's founding principle has always been centered on research and development, leading to the creation of several internationally patented products. With a dedicated R&D laboratory and a team of expert engineers, GES Dokum continuously develops new formulations and product designs tailored to the evolving needs of modern foundries. The company employs between 16 and 25 highly skilled professionals who oversee every stage of production, from raw material procurement to final quality inspection and customer delivery.
| Detail | Information |
| Company Name | GES Foundry Products and Metallurgy |
| Year Established | 2004 |
| Industry Experience | 30+ Years (Combined) |
| Facility Area | 12,000 m2 (Indoor + Outdoor) |
| Annual Production Capacity | 12,000,000 Units |
| Location | Beykoy, Duzce, Turkey |
| Certifications | ISO 9001:2008, OHSAS 18001:2007 |
| Number of Employees | 16 - 25 |
| Website | gesdokum.com.tr |
2. Products and Product Range
GES Dokum manufactures a comprehensive range of foundry consumables designed to optimize the metal casting process. The company's product portfolio is organized into three primary categories: Mini Risers, Exothermic Feeder Sleeves, and Cover Powders. Additionally, GES Dokum produces complementary products including Shell Breakers and Metal Breakers that are essential for the efficient removal of riser systems from finished castings. Each product category includes multiple models, material compositions, and size variations, allowing foundries to select the optimal solution for their specific casting requirements.
The company's product development philosophy is rooted in the understanding that every foundry has unique operational parameters, including metal composition, pouring temperatures, mold designs, and casting geometries. To address this diversity, GES Dokum maintains the capability to produce custom-sized mini risers and exothermic feeder sleeves in its specialized chamber facility. This flexibility enables the company to respond quickly to customer-specific requirements while maintaining the same high quality standards that characterize its standard product lines. All products undergo rigorous testing, including temperature analysis and pressure resistance evaluations, before they are approved for mass production.
| Product Category | Model / Type | Base Material | Application |
| Mini Risers | B Type | Fluorine Free | Iron & Steel Casting |
| Mini Risers | DB Type | Fluorine Free | Iron & Steel Casting |
| Mini Risers | BS Type | Sodium Silicate Based | Iron & Steel Casting |
| Mini Risers | KB Type | Resin Based | Iron & Steel Casting |
| Mini Risers | DBS Type | Fluorine Free | Iron & Steel Casting |
| Exothermic Feeders | KX Type | Sand Based | Iron & Steel Casting |
| Exothermic Feeders | KXS Type | Fiber Based | Iron & Steel Casting |
| Exothermic Feeders | KXSX Type | Fiber Based | Iron & Steel Casting |
| Exothermic Feeders | KXK Type | Sodium Silicate Based | Iron & Steel Casting |
| Exothermic Feeders | OXK Type | Special Production | Iron & Steel Casting |
| Exothermic Feeders | Box Type | Sand Based | Iron & Steel Casting |
| Cover Powder | EXOPOWDER 01 | Exothermic | Feeder Insulation |
| Shell Breakers | For Mini Risers | Mechanical | Riser Removal |
| Shell Breakers | For Exothermic KX | Mechanical | Riser Removal |
| Shell Breakers | For Exothermic OKX | Mechanical | Riser Removal |
| Metal Breakers | For Mini Risers | Mechanical | Riser Removal |
3. Mini Risers - Detailed Analysis
Mini Risers represent one of GES Dokum's flagship product lines and are widely regarded as a breakthrough innovation in foundry consumable technology. Due to their exceptional high exothermic properties, Mini Risers deliver significantly higher feeding capacities compared to conventional exothermic feeders. In practical foundry applications, Mini Risers demonstrate approximately 60 to 70 percent greater productivity than standard exothermic feeders, making them an extremely cost-effective solution for iron and steel casting operations. This superior performance is attributed to their unique structural composition, which generates intense and sustained exothermic reactions during the casting process.
One of the most distinctive advantages of Mini Risers is their compact form factor. Thanks to their innovative design, Mini Risers can be deployed in the production of small and tightly configured casting pieces where conventional exothermic feeders cannot be easily positioned. This capability opens up new possibilities for foundries working with intricate casting geometries, allowing them to maintain high feeding efficiency even in space-constrained mold configurations. GES Dokum produces Mini Risers in five distinct models (B Type, DB Type, BS Type, KB Type, and DBS Type), each offering different base material compositions and performance characteristics to suit various casting scenarios.
| Model | Shape / Feature | Base Material | Primary Use Case |
| B Type | Standard cylindrical | Fluorine Free | General purpose small castings |
| DB Type | Cylindrical with break feature | Fluorine Free | Medium complexity castings |
| BS Type | Sodium silicate bonded | Sodium Silicate Based | High precision castings |
| KB Type | Resin bonded chamber | Resin Based | Special dimension castings |
| DBS Type | Premium cylindrical | Fluorine Free | High performance feeding |
The B Type Mini Riser is the standard cylindrical model designed for general-purpose small casting applications. It utilizes a fluorine-free formulation, making it environmentally friendly and compliant with increasingly strict workplace safety regulations. The DB Type incorporates a built-in break feature that simplifies the removal process after casting, reducing post-processing time and labor costs. The BS Type employs a sodium silicate bonding system for enhanced dimensional accuracy, while the KB Type uses a resin-bonded chamber for specialized applications requiring precise internal geometries. The DBS Type represents the premium tier, combining the break feature of the DB series with enhanced feeding performance for demanding casting operations.
4. Exothermic Feeder Sleeves - Detailed Analysis
Exothermic Feeder Sleeves constitute the second major product line manufactured by GES Dokum and are essential components in the iron and steel casting industry. These products are designed to maintain molten metal in a liquid state within the riser cavity for extended periods, thereby ensuring adequate feeding of the casting to compensate for shrinkage during solidification. GES Dokum produces a wide variety of exothermic feeder sleeves in different shapes, sizes, and material compositions to accommodate the diverse requirements of modern foundry operations. The company's ability to produce both standard catalog items and custom-designed feeder sleeves sets it apart from many competitors in the global market.
The exothermic reaction generated by these feeder sleeves creates a sustained heat source that dramatically slows the cooling rate of the molten metal, preventing premature solidification and the formation of shrinkage defects such as porosity and internal voids. GES Dokum offers six distinct models of exothermic feeders: KX Type (sand-based, cylindrical), KXS Type (fiber-based with enhanced shell), KXSX Type (fiber-based, large casting), KXK Type (square cross-section for tight spaces), OXK Type (custom shapes for special applications), and Box Type (rectangular for large surface area feeding). Each model is engineered to deliver optimal thermal performance for specific casting scenarios, and all can be customized in terms of dimensions and exothermic intensity.
| Model | Shape | Base Material | Application |
| KX Type | Cylindrical | Sand Based | Standard iron & steel casting |
| KXS Type | Cylindrical with shell | Fiber Based | High insulation requirement |
| KXSX Type | Enhanced cylindrical | Fiber Based | Large casting pieces |
| KXK Type | Square cross-section | Sodium Silicate Based | Tight space applications |
| OXK Type | Custom shape | Special Production | Customer-specific geometries |
| Box Type | Rectangular | Sand Based | Large surface area feeding |
The KX Type is the workhorse of the product line, offering reliable performance for standard iron and steel casting applications. The KXS and KXSX models incorporate fiber-based construction for superior thermal insulation, making them ideal for applications where extended feeding times are required. The KXK Type features a square cross-section design that is particularly advantageous in foundries where mold space is limited, as it maximizes the feeding volume within a compact footprint. The OXK Type represents GES Dokum's custom production capability, where feeder sleeves are designed and manufactured to exact customer specifications, including non-standard geometries and performance parameters. The Box Type, with its rectangular profile, is optimized for casting applications requiring large surface area coverage and uniform heat distribution.
5. Cover Powder (EXOPOWDER 01)
EXOPOWDER 01 is a specialized exothermic cover powder developed and manufactured by GES Dokum for application on the exposed surface of molten metal in feeder cavities during the casting process. This product performs multiple critical functions simultaneously: it prevents shrinkage defects by maintaining the temperature of the molten metal, provides high thermal insulation by forming a thin protective crust on the hot metal surface, and prevents rapid cooling that could lead to premature solidification. The powder achieves these effects through an instantaneous exothermic reaction when it comes into contact with the molten metal, generating additional heat that extends the liquid holding time of the riser.
The application of EXOPOWDER 01 is straightforward and can be integrated into existing foundry workflows with minimal disruption. The powder is simply applied as a coating on the feeder opening during or immediately after the pouring process. Upon contact with the hot metal, the powder expands and forms a rigid, insulating crust that seals the feeder opening and dramatically reduces heat loss through radiation and convection. This dual action of exothermic heating and physical insulation makes EXOPOWDER 01 one of the most effective cover powders available in the market, and it is compatible with all types of exothermic feeder sleeves and mini risers produced by GES Dokum as well as with third-party feeding systems.
6. Shell and Metal Breakers
In addition to its core product lines of mini risers and exothermic feeder sleeves, GES Dokum manufactures a range of shell breakers and metal breakers that are essential tools for the post-casting removal process. After the casting has solidified and cooled, the riser systems must be separated from the finished casting. This removal process can be time-consuming and labor-intensive without the proper tools, particularly when dealing with the hardened exothermic shells that encase the riser metal. GES Dokum's breakers are specifically designed to fracture these shells efficiently, reducing the time and effort required for riser removal while minimizing the risk of damage to the casting itself.
The product range includes Shell Breakers for Mini Risers, Shell Breakers for Exothermic KX Feeders, Shell Breakers for Exothermic OKX Feeders, and Metal Breakers for Mini Risers. Each breaker type is engineered to match the specific dimensions and material properties of the corresponding riser or feeder model, ensuring optimal breakage performance. The shell breakers are designed to crack and fragment the hardened exothermic shell material, while the metal breakers are specifically calibrated to shear the solidified metal core of the mini risers. By offering these complementary products alongside its main product lines, GES Dokum provides foundries with a complete end-to-end solution for their feeding and post-casting processing needs.
7. Manufacturing and Quality
GES Dokum's manufacturing operations are governed by a rigorous quality management system that complies with ISO 9001:2008 and OHSAS 18001:2007 international standards. The company's quality philosophy is encapsulated in its guiding principle: "Quality is not a destination, it is an ongoing process." This principle is implemented through comprehensive quality control procedures that span every stage of the production cycle, from the procurement of raw materials and auxiliary production components through to the final delivery of finished products to customers.
Before any product enters mass production, it undergoes extensive testing in GES Dokum's dedicated laboratory facility. This testing includes temperature analysis to verify the exothermic performance characteristics of each product batch, as well as pressure resistance testing to ensure structural integrity under the extreme conditions encountered during the casting process. Additionally, newly developed products are subjected to operational trials in collaboration with partner foundries, where they are tested in actual casting templates under real production conditions. This practical validation approach ensures that every product released by GES Dokum performs reliably in the demanding environment of industrial metal casting operations.
The company's R&D laboratory plays a central role in its continuous improvement strategy. Staffed by experienced metallurgists and materials scientists, the laboratory is equipped with advanced testing instruments that enable precise characterization of raw materials, product formulations, and finished product performance. GES Dokum holds several international patents for its innovative product designs, and the R&D team is continuously working on developing next-generation foundry consumables that address emerging challenges in the global casting industry, such as the demand for fluorine-free formulations, improved recyclability of riser materials, and enhanced energy efficiency in the exothermic reaction process.
8. Export Markets and Global Presence
GES Dokum has established a significant global footprint in the foundry consumables market, exporting its products to foundries across multiple continents. According to international trade profiles, the company's main export markets span the Americas, Asia, Europe, and the Middle East, with a reach that extends to foundries worldwide. This broad international presence is a testament to the competitive quality and reliability of GES Dokum's product range, as well as the company's ability to meet the diverse technical requirements and regulatory standards of different regional markets.
The company supports its international customer base through multilingual product documentation, with product catalogs available in English, German, French, and Polish languages. This multilingual approach reflects GES Dokum's commitment to serving foundries in non-Turkish-speaking markets and facilitating technical communication with international buyers. The availability of detailed product catalogs in multiple languages, combined with the company's willingness to produce custom-designed products, positions GES Dokum as a flexible and customer-oriented supplier capable of meeting the specific needs of foundries operating in different countries and regulatory environments. The company's export strategy continues to expand, with ongoing efforts to penetrate new markets and strengthen its presence in existing ones through participation in international foundry trade fairs and exhibitions.
9. Contact Information
| Role | Name | Phone | |
| Technical Consultant | Dr. Murat Colak | +90 542 410 10 61 | murat@gesdokum.com.tr |
| General Manager | Muhittin Gundogdu | +90 380 551 26 30 | muhittin@gesdokum.com.tr |
| General Inquiries | GES Dokum | +90 380 551 26 30 | info@gesdokum.com.tr |
Address: Istiklal Mahallesi, 12. Cadde No: 12, 81600 Beykoy - Duzce - Turkey
Website: gesdokum.com.tr
10. Frequently Asked Questions (FAQ)
What is GES Dokum and what does the company produce?
GES Foundry Products and Metallurgy (GES Dokum) is a Turkish manufacturing company established in 2004 that specializes in producing foundry consumables including mini risers, exothermic feeder sleeves, cover powders, and shell and metal breakers. The company operates from a 12,000 m2 facility in Duzce, Turkey, with an annual production capacity of 12 million units, serving foundries in the iron and steel casting industries worldwide.
What is the difference between Mini Risers and Exothermic Feeder Sleeves?
Mini Risers are compact, high-exothermic feeding devices that deliver 60-70 percent greater productivity compared to conventional exothermic feeders. They are specifically designed for small and tightly configured casting pieces where standard feeders cannot fit. Exothermic Feeder Sleeves are larger feeding systems available in a wider variety of shapes (cylindrical, square, rectangular, and custom) designed for general iron and steel casting applications where sustained thermal insulation is required.
What quality certifications does GES Dokum hold?
GES Dokum operates under ISO 9001:2008 quality management system certification and OHSAS 18001:2007 occupational health and safety management system certification. The company conducts comprehensive quality inspections covering every stage of production, from raw material procurement to final product delivery, and performs temperature analysis and pressure resistance testing on all products before mass production.
Can GES Dokum produce custom-sized products for specific foundry requirements?
Yes, GES Dokum has a dedicated chamber facility capable of producing mini risers and exothermic feeder sleeves in custom dimensions and specifications upon customer request. The company's R&D laboratory works closely with partner foundries to develop and test new products in actual casting templates, ensuring that custom solutions meet the exact performance requirements of each application.
What is EXOPOWDER 01 and how is it used in the casting process?
EXOPOWDER 01 is an exothermic cover powder manufactured by GES Dokum that is applied to the surface of molten metal in feeder cavities during casting. It prevents shrinkage by forming an insulating crust on the hot metal surface, and it generates additional heat through an exothermic reaction upon contact with molten metal. This dual action maintains the metal in a liquid state for longer periods, preventing rapid cooling and ensuring complete feeding of the casting.
Which countries and regions does GES Dokum export to?
GES Dokum exports its foundry consumables to foundries across the Americas, Europe, Asia, and the Middle East. The company provides multilingual product catalogs in English, German, French, and Polish to support its international customer base, and continues to expand its global market presence through trade fair participation and direct engagement with international foundries.
What are shell breakers and metal breakers used for?
Shell breakers and metal breakers are tools manufactured by GES Dokum for the post-casting removal of riser systems from finished castings. Shell breakers are designed to fracture and fragment the hardened exothermic shell material surrounding the riser, while metal breakers are calibrated to shear the solidified metal core of mini risers. These tools significantly reduce the time and labor required for riser removal during post-casting processing.
11. Summary
GES Foundry Products and Metallurgy stands as one of Turkey's premier manufacturers of foundry consumables, with a product portfolio that addresses the critical needs of modern iron and steel casting operations. The company's 30 years of combined industry experience, combined with its state-of-the-art 12,000 m2 production facility and 12 million unit annual capacity, positions it as a reliable and scalable supplier for foundries of all sizes around the world. GES Dokum's commitment to innovation is evidenced by its portfolio of internationally patented products and its active R&D program focused on developing next-generation foundry solutions.
The company's comprehensive product range, spanning Mini Risers (5 models), Exothermic Feeder Sleeves (6 models), Cover Powders, and Shell and Metal Breakers, provides foundries with a complete feeding and post-casting solution from a single supplier. The availability of custom production capabilities, multilingual technical documentation, and certifications to ISO 9001:2008 and OHSAS 18001:2007 standards further reinforces GES Dokum's position as a quality-driven, customer-focused manufacturer. With established export channels across the Americas, Europe, Asia, and the Middle East, GES Dokum continues to expand its global footprint while maintaining the high product quality and technical support standards that have defined its reputation in the foundry industry.
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