Maximise aluminium yield and cut casting costs with a focus on furnace efficiency

Metal loss and excessive energy consumption are two of the biggest threats to aluminium die casting profitability. Depending on aluminium grade, a metal loss of just 1% of an annual melting output of 5,000 tonnes could equate to an average financial loss of 70,000 EUR, while around 25% of the total cost of die cast parts is associated with energy consumption.

Both are common issues that can be readily addressed by focussing on melting and dosing furnace processes and efficiency.

New guidance developed by StrikoWestofen seeks to help aluminium die casters tackle these specific cost drivers by identifying where problems can occur and the technical solutions available to help remedy them.

The metal yield guide spans melting, transfer and dosing, and examines how losses due to oxidation, spillage and contamination (impacting quality and therefore potential scrap rate) can all be minimised. The guide also includes advice on how aluminium die casters can cut metal loss by reducing the overall number of processes involved.

Also featured in the resource series, ‘5 ways to save energy when melting and transferring metal’ provides advice on reducing energy consumption.

The downloadable guide looks specifically at savings linked to data monitoring, optimizing melting furnace shaft fill, melting periods during low utilisation, energy efficient metal transfer and dosing and at maintenance measures.

The free resources are part of its Foundry Efficiency support series and can be found at