The Essen foundry tests a prototype furnace to boost efficiency, safety, and ergonomics

Innovative Approaches for More Efficient Melting Furnaces in Essen
The team at the Essen foundry is testing a new concept for our melting furnaces. The prototype will undergo a one-year trial – with exciting results for the future!

The Essen foundry is currently working on a groundbreaking project: the team is developing a new concept for our melting furnaces to significantly increase the efficiency and ergonomics of the foundry. Furnace 007 has been selected as the test subject, where the planned improvements are being implemented and thoroughly tested. The results of this trial phase will determine whether the concept will be rolled out to the other furnaces.

One of the most important innovations is increasing the furnace's capacity. This would allow larger batches of aluminum to be processed in a single operation, significantly boosting the foundry's productivity. To achieve this, the casting furnace’s capacity must also be adjusted – a challenging task for the entire team.

Focus on Safety and Usability

In addition to increasing capacity, the new concept prioritizes safety and user-friendliness. Planned improvements include:

  • Self-sealing, spring-loaded steel beams to optimize the door seals.
  • A 15 cm door height increase to improve the handling of solid metal.
  • A raised door threshold to allow positioning of the dross container even with the door closed.
  • Modified support components to make dross removal more efficient.

The team is working tirelessly on the implementation and initial tests. If the prototype meets expectations, the new melting furnaces could make the foundry not only more efficient but also safer and more ergonomic – a win for both employees and the company.