Wuxi Wondery Industry Equipment Co., Ltd

In Hungary, a medium-sized aluminum foundry supplying automotive and machinery customers was struggling with an aging gas melting furnace. As natural gas prices climbed and customers demanded more consistent castings, the old system became a serious bottleneck: low melting efficiency, unstable metal quality, and rising energy bills were eroding profit margins. To break this pattern, the plant decided to upgrade to an Oval Crucible Gas Aluminum Melting Furnace with a maximum capacity of 1200KG per heat, custom-configured to attack their biggest pain points: high fuel consumption, slow melting, and high scrap rates. 1. Hungarian customer pain points: not just “an old furnace” Before the upgrade, the foundry faced several issues that had become increasingly hard to ignore: Energy cost pressure from rising gas prices The old furnace had poor insulation and outdated burner layout. To maintain molten aluminum, the plant had to burn a lot of gas, especially during long holding periods. The energy cost per ton of aluminum was becoming uncompetitive. Limited melting capacity and slow response to peak orders Each heat was relatively small, so the plant often needed to run multiple furnaces and extra shifts during peak demand. This increased labor intensity, floor space usage, and safety risk on the melt deck. Unstable metal quality and high scrap rate Inconsistent temperature distribution and strong oxidation in the bath led to more dross and more internal defects in castings (porosity, inclusions). The team compensated with overspecification, extra grinding, and rework—consuming time that should have been used for productive output. These pain points combined into a simple reality: every extra kilowatt-hour and every percentage point of scrap was directly cutting into profit on each casting. 2. The 1200KG Oval Crucible Gas Aluminum Melting Furnace solution To address these issues, we supplied a 1200KG Oval Crucible Gas Aluminum Melting Furnace (Gas Aluminum Melting Furnace) tailored to the foundry’s product mix and layout. Oval crucible geometry for higher flame coverage and faster melting Compared with a traditional round crucible, the oval crucible gives the gas flame more effective contact area along the crucible wall. Aluminum ingots and returns can be stacked more compactly, reducing “cold spots” and shortening the time from cold charge to pouring temperature. Bath depth and surface area were matched to the Hungarian customer’s typical ladle size and pouring rhythm, ensuring a stable, continuous supply of clean metal. 1200KG single-furnace capacity: replace multi-furnace operation With up to 1200KG per heat, one furnace can now do the work that previously required two or more small units during busy periods. The larger single charge supports consolidated melting and coordinated pouring to multiple molds, instead of constantly starting and stopping several smaller furnaces. This directly reduces operator headcount around the furnace area and simplifies production scheduling. Optimized gas system and insulation: directly targeting energy cost Burners and flame passages were arranged to guide the flame around the crucible in a controlled loop, improving heat transfer and reducing wasted exhaust heat. A multi-layer refractory and insulation package reduces heat loss, especially during holding periods and overnight operation. Gas flow and air ratio can be finely adjusted to match the local gas quality and pressure in Hungary, ensuring clean combustion and consistent performance. Easy operation and maintenance A large top opening and lifting points simplify charge loading and crucible maintenance. The control panel includes pre-set melting and holding recipes; operators select the program rather than manually “guessing” settings. Standardized wear parts make it easy for the customer to stock or source spares locally. 3. Results after installation: energy, scrap and scheduling all improved After the 1200KG Oval Crucible Gas Aluminum Melting Furnace was commissioned and integrated into daily production, the Hungarian foundry reported clear improvements: Lower energy consumption per ton of aluminum With better insulation and a more efficient flame path, the gas required to produce the same amount of molten metal dropped significantly. This was especially noticeable on night shifts and during long holding periods—“less gas burned, more heat kept in the bath.” More stable metal quality and reduced scrap More uniform bath temperature and a calmer metal surface reduced oxidation and dross formation. Internal defects in castings decreased, and the scrap/rework rate fell. As a result, more of the foundry’s capacity is now used for first-pass good parts instead of rework. Smoother line organization and fewer furnace start-stops The 1200KG capacity now matches the rhythm of the holding furnace and pouring line. The plant can plan melts in larger, predictable blocks, reducing the need to frequently start and stop multiple furnaces. This makes delivery schedules more reliable and simplifies shop-floor management. 4. Takeaways for Hungarian aluminum foundries For aluminum foundries in Hungary facing both high energy prices and quality pressure, upgrading to a 1200KG Oval Crucible Gas Aluminum Melting Furnace is more than a simple equipment replacement. It is a way to: Use higher thermal efficiency to offset gas price increases; Use larger single-furnace capacity to reduce multi-furnace labor and complexity; Use more stable molten aluminum quality to lower scrap and protect delivery performance.  

1. Project background: higher scrap ratio, melt quality becomes a hidden killer This Russian aluminum die casting plant mainly produces automotive components and machine housings. To reduce raw material cost, they have been steadily increasing the proportion of scrap aluminum and return material in their charge. But several problems started to intensify: More internal gas porosity and inclusions – X-ray inspections showed a rising reject rate due to internal defects. Faster mold erosion and sticking – dirty metal increased chemical and mechanical attack on mold surfaces, shortening mold maintenance intervals and increasing downtime. Changing furnaces alone did not solve the problem – even with better melting furnaces, the root cause remained: the plant lacked a robust in-line aluminum melt purification step. The management realized that without Aluminum Degassing & Dross Removal between the holding furnace and casting, it would be very hard to hit their scrap-rate targets. They decided to evaluate an Aluminum Degassing Machine / Aluminum Degassing & Dross Removal Machine to clean the melt online. 2. Solution: in-line degassing and dross removal tailored to die casting Based on the holding furnace design and casting cycle, we installed an Aluminum Degassing & Dross Removal Machine at the outlet of the holding furnace: Rotary degassing unit A rotary degassing system injects inert gas into the melt, creating fine bubbles that capture dissolved hydrogen and bring it to the surface. This significantly reduces gas porosity risk, which is especially critical when using a high ratio of scrap aluminum. Fluxing plus mechanical dross removal The system combines flux injection with dedicated skimming tools to remove oxide films and non-metallic inclusions from the melt. Cleaner aluminum means fewer inclusions carried into the die cavity and less risk of internal defects. Mechanical design adapted to Russian shop-floor conditions The machine structure was designed for limited furnace-front space, typical operator habits, and local maintenance capabilities. Inlet and outlet heights match the existing holding furnace and casting system, so the plant did not need a major layout rebuild to integrate the unit. Process visibility and adjustable parameters Operators can adjust rotor speed, gas flow and treatment time according to alloy grade, scrap ratio and line takt time. This allows targeted melt purification for different alloys and batch conditions instead of a “one-size-fits-all” setting. 3. Results: higher first-pass yield and more controlled mold life After a period of production with the Aluminum Degassing & Dross Removal Machine, the Russian die casting plant reported: Significant reduction in internal defects X-ray pass rates improved, and the main defects shifted away from gas porosity/inclusions toward more manageable dimensional issues. This raised first-pass yield and reduced scrap and rework. Less mold erosion and sticking Cleaner metal reduced attack and build-up on mold surfaces, extending mold maintenance intervals and cutting unplanned downtime. Higher effective scrap utilization With more reliable melt cleanliness, the plant became confident in using a higher proportion of scrap and return material without sacrificing quality. This directly lowered raw material cost per good casting.

1. Project background: sensitive aluminum prices, unstable ingot output This Russian scrap aluminum recycling company mainly collects scrap from car dismantling and machining shops, melts it, and sells aluminum ingots to local aluminum die casting plants and export customers. However, their original small casting line had several serious weaknesses: Unstable hourly output – manual pouring and a short casting line made the real capacity fluctuate a lot, especially under rush orders. Non-standard ingot sizes – different molds and inconsistent pouring caused size variation, which made stacking, palletizing and container loading inefficient. Insufficient cooling and internal stress issues – because the line was short and cooling was not well controlled, some ingots showed surface shrinkage and hidden internal stress, and die casting customers were not fully satisfied. The management wanted a standardized 9m Aluminum Ingot Casting Machine line that could stabilize 2–3 tons per hour and produce ingots that meet both the Russian market and export packaging standards. 2. Solution: 9m Aluminum Ingot Casting Machine with 2–3t/h continuous casting Based on the customer’s furnace capacity and plant layout, we supplied a 9m Aluminum Ingot Machine / Aluminum Ingot Casting Machine as a complete casting line: 2–3 tons per hour design capacity The line was engineered for a continuous casting rate of 2–3t/h, matched to the output of the existing melting and holding furnaces. This avoids situations where the furnace is waiting for the line or the line is waiting for molten metal, making production planning and shift assessment much easier. Ingot molds customized to Russian die casting habits Mold dimensions were designed according to sizes commonly used by Russian aluminum die casting plants. This makes it easier for their automatic de-palletizing and charging systems, and at the same time helps the recycler create standard pallets with higher storage and container loading efficiency. Automated pouring, cooling, de-molding and ingot flipping The 9m ingot casting machine handles automatic pouring, vibration cooling, de-molding and flipping of ingots. Operators mainly supervise and handle strapping/packing instead of doing heavy manual pouring. For Russian companies facing rising labor costs and a shortage of skilled furnace operators, this reduction in manual dependence is a major advantage. 3. Results: from “scrap collector” to “stable aluminum ingot supplier” After commissioning, the Russian customer saw clear benefits: Stable 2–3t/h output of standard ingots – they can now commit to more long-term contracts without frequently pushing back delivery dates due to unstable capacity. Uniform ingot size and neat stacking – pallets are cleaner, container loading is faster, and the company has a stronger position when negotiating with local and export buyers. Business role upgrade – instead of being seen only as a scrap collector, the company is increasingly recognized as a “reliable aluminum ingot supplier” in the local aluminum die casting supply chain.