By Manager Ding | Sales Manager, Juding Thermal Energy Technology
Background
In May 2021, I received an inquiry from a die-casting plant in Guangdong Province. The plant manager, Mr. Chen, had a clear problem: their existing melting operation was inefficient, unsafe, and unable to keep up with production.
They were running three 2,200-ton L.K. die-casting machines in a single workshop. Their current setup relied on manual ladling from a fixed furnace—a method that was not only slow but also dangerous. Workers had to stand close to the molten aluminum, using long-handled ladles to transfer metal into the shot sleeves. Splashes and burns were a constant risk.
Mr. Chen told me: “We need a safer way to deliver aluminum. And we need at least 3 tons per hour to keep all three machines running.”
That conversation started a project that would transform their melting operation.
The Challenge
The plant faced three critical issues:
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Safety Hazards: Manual ladling exposed workers to extreme heat and molten metal splashes. The plant had recorded several near-miss incidents and one minor burn injury in the past year.
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Production Bottleneck: The existing furnace could not deliver enough aluminum to keep pace with three 2,200-ton machines. Production was often delayed waiting for metal.
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Temperature Consistency: Manual transfer caused significant temperature loss, leading to inconsistent quality and higher scrap rates.
The Solution: QDW Series Tilting Furnace
After reviewing their production data, I recommended the QDW Series Tilting Furnace with a capacity of 3 tons per hour.
Here’s why it was the right fit:
1. Safety First: “Human-Aluminum Separation”
The QDW tilting design eliminates the need for manual ladling. The furnace body tilts smoothly, and molten aluminum flows directly through a launder into the shot sleeve. The operator controls the process from a safe distance—no more standing next to the furnace with a ladle.
This was the most important factor for Mr. Chen. He wanted his workers out of harm’s way.
2. 3 Tons per Hour: Matching Production Demand
The QDW furnace was configured to deliver 3 tons of aluminum per hour, which perfectly matched the demand of three 2,200-ton L.K. machines running simultaneously. No more waiting. No more production delays.
3. ±5℃ Temperature Control
The QDW’s precise temperature control (±5℃) ensured that the aluminum arrived at the shot sleeve at the correct temperature every time. This reduced porosity and improved part quality.
4. Low Burn Loss
With burn loss of only <0.8%-1.3% , the plant saved money on every melt. Over a year, this added up to significant savings.
Project Timeline: From Inquiry to Acceptance
May 2021 – Initial Inquiry
Mr. Chen contacted us through our website. We had an initial call to discuss his production requirements and pain points.
June 2021 – On-Site Assessment
I traveled to Guangdong to visit the plant, inspect their workshop layout, and meet with the production team. We reviewed their melting data and confirmed the QDW model selection.
July 2021 – Proposal and Customization
We submitted a detailed proposal, including technical specifications, layout drawings, and a cost-benefit analysis. The plant requested minor customizations to fit their existing charging system.
August 2021 – Order Confirmed
The contract was signed. Production of the QDW furnace began at our facility in Changshu, Suzhou.
October 2021 – Delivery and Installation
The furnace was shipped to Guangdong and installed by our technical team. Installation took approximately two weeks, including connection to their existing exhaust system and power supply.
November 2021 – Commissioning and Training
We conducted a full commissioning process, including test melts and temperature calibration. We also trained the plant’s operators on safe operation, daily maintenance, and troubleshooting.
December 2021 – Final Acceptance
After a month of trial production, the plant formally accepted the equipment. The QDW furnace had met all performance targets:
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Melting capacity: 3 tons per hour ✅
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Temperature accuracy: ±5℃ ✅
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Burn loss: <1.0% ✅
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Zero safety incidents since installation ✅
Results After Implementation
Six months after installation, I followed up with Mr. Chen. Here’s what he told me:
Safety:
“This was the best decision we made. Our workers are no longer exposed to molten metal. We’ve had zero burns, zero near-misses. The team feels much safer, and morale is higher.”
Production:
“We’re now feeding all three 2,200-ton machines without any delays. The tilting furnace delivers exactly what we need, when we need it. Our overall efficiency is up by at least 30%.”
Quality:
“The temperature consistency is much better. Our scrap rate has dropped noticeably. Customers are happy with the quality.”
Maintenance:
“Cleaning is much easier now. The tilting design lets us drain almost all the residual aluminum. What used to take hours now takes minutes.”
Key Takeaways
This case demonstrates how the right furnace can transform a die-casting operation:
| Challenge | QDW Solution | Result |
|---|---|---|
| Manual ladling safety risks | Tilting discharge with human-aluminum separation | Zero injuries, safer workplace |
| Insufficient melting capacity | 3 tons/hour capacity | Matched three 2,200-ton machines |
| Temperature inconsistency | ±5℃ control accuracy | Lower scrap rate, better quality |
| High burn loss | <0.8%-1.3% burn loss | Significant material savings |
| Difficult cleaning | Tilting design for complete drainage | Faster cleaning, less downtime |
Is Your Plant Facing Similar Challenges?
If you’re running multiple die-casting machines and struggling with safety, capacity, or quality, the QDW Series Tilting Furnace could be the solution you need.
I’m happy to discuss your specific requirements and help you find the right configuration.
Contact me directly:
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Sales Manager: Manager Ding
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Phone/WeChat: 15962220217
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Address: No. 30, Anfu Road, Northern Industrial Zone, Dongbang Town, Changshu City, Jiangsu Province, China
Scan the QR code to add me on WeChat for a free consultation and customized solution.
