How to cut furnace costs

Looking into cost savings can have a significant impact on your business. In this article, we provide you with essential tips on how to tackle your foundry's energy hot spots by e.g. lowering carbon emissions and cutting energy consumption in your aluminum foundry to ultimately improve profitability and cost-efficiency. 

Qualified tips on how to cut furnace costs

Leveraging data becomes crucial in identifying areas for improvement. For instance, using furnace load cells to track material weight and energy consumption can unveil performance inefficiencies, especially in filling and distribution.

Shaft melting furnaces stand out as energy-efficient, employing a counter-flow principle to optimize the melting process. A balanced ratio of returns and ingots as well as the use of smaller ingots maximize energy use and metal yield.

Operating at a high capacity boosts energy efficiency, but it is common for foundries to melt below full capacity due to various reasons. Maintenance plays a pivotal role in curbing energy consumption, with small adjustments like maintaining furnace door seals, correcting spare parts, or optimizing burner efficiency, contributing to significant savings.

Efficient transfer systems, such as closed ladles and dosing systems, minimize heat loss and enhance metal quality, ultimately optimizing energy use and productivity.

Did you know? 

Aluminum die-casting operations demand considerable energy, with about a quarter of the cost linked to energy usage.

The melt shop alone can gulp down as much as 77% of a die-casting foundry's overall energy consumption.

Are you interested in more tips on how to cut furnace costs? Then contact us below to learn more about what we can do for you.