Rotary furnaces are the workhorses of aluminium recycling. They handle contaminated scrap, dross, and low-grade material that other furnaces cannot process economically. But they are also energy-intensive. In my 25 years, I have seen rotary furnaces co...

In late 2023, I was contacted by a die casting plant in Rayong, Thailand. They supply structural components for electric vehicles — battery trays, motor housings, and front shock towers. Their main customer is a Chinese OEM that has invested heavily in...

In early 2023, a mid-sized foundry in Jiangsu Province contacted me. They run two gas-fired reverberatory furnaces, each with a 5-tonne capacity. They melt around 25 tonnes per day of ADC12 and A380 for automotive and industrial castings. Their energy ...

In late 2022, I received an email from a foundry manager in Indiana, USA. He had found my blog through a search for “aluminium furnace maintenance checklist.” His message was short: “Our maintenance costs are out of control. We run two gas-fired reverb...

In early 2023, I received a call from a die casting plant in Shanghai. They were running two gas-fired reverberatory furnaces, each with a capacity of 3 tonnes. They melted around 18 tonnes per day of ADC12 alloy. Their energy bill had risen ...

The electric vehicle has changed the die casting furnace more in five years than the internal combustion engine did in fifty. That is not an exaggeration. When Tesla introduced the first “gigacast” rear underbody in 2019, it set off a chain reaction th...

Troubleshoot why your aluminium furnace is using more gas than usual. Check burner, gas pressure, lining, and operation. 25 years of foundry experience. A sudden jump in gas consumption is almost never the gas meter’s fault. It is a signal t...

Practical guide to optimising burner efficiency in gas-fired aluminium furnaces. 25 years of foundry experience. Cut fuel costs, reduce emissions, improve melt quality. Optimising burner efficiency comes down to four things: correct air-fuel ratio, re...