A medium-sized steel foundry in Ahmedabad, Gujarat, has successfully overcome a long-standing issue of frequent refractory lining failures. By integrating the Model X Lining Vibrator from LeisterTech into their process, the facility extended the lifespan of its induction furnace lining by over 60%, significantly reducing downtime and saving over ₹6 lakhs annually.
The Challenge: Lining Failure After Just 18–20 Heats
The foundry operated a 3-ton induction furnace, producing alloy castings for the automotive sector. Despite using high-quality refractory material, linings routinely failed after only 18 to 20 heats. The company relied on manual ramming, which caused:
- Inconsistent compaction, especially at the base of the crucible
- Operator fatigue and uneven pressure
- Cracks developing as early as the 12th heat
- Production downtime of 3–4 days every month
- Over 12% refractory material wastage per batch
These problems were affecting both efficiency and profitability.
The Solution: Mechanical Vibration with Model X
The foundry engaged with LeisterTech’s engineering team for a free technical audit. Based on the assessment, the Model X Lining Vibrator was recommended and custom-calibrated for the foundry’s furnace type and refractory mix.
Key Custom Features:
- Adjustable RPM (2200–2800) for precise compaction
- Wider vibration head to match the crucible radius
- Portable, reinforced base for flexible positioning
- On-site operator training by LeisterTech experts
Want to explore the specs? Click here to view Model X features
Results: Improved Efficiency in Just 60 Days
The transformation was clear within two months of installation:
Performance MetricBeforeAfter Using LeisterTech VibratorLining Lifespan18–20 heats29–32 heatsMonthly Downtime3–4 daysLess than 1 dayRefractory Waste~12% per batchUnder 5%Operator FatigueHighSignificantly ReducedAnnual Maintenance Cost₹8.5 Lakhs₹2.4 Lakhs
“We didn’t realize how much efficiency we were losing until we switched to mechanical compaction. The difference was night and day.”
– Foundry Manager, Ahmedabad
Why This Works: Smarter Compaction, Longer Life
LeisterTech’s mechanical lining vibrator ensures consistent compaction and eliminates human variability, which reduces cracks and voids. This is a cost-effective upgrade that avoids the need for expensive automation systems.
Benefits at a Glance:
- Uniform lining thickness
- Reduced material consumption
- Minimized dependency on manual skill
- Adaptable for any furnace size or refractory mix
🔗 Comprehensive Support From LeisterTech
LeisterTech isn’t just about selling equipment. They provide end-to-end support to ensure optimal performance and durability of furnace linings.
Included Services:
- Lining audits and compaction analysis
- On-site vibration demos
- Operator training and annual servicing
- Product customization and upgrades
📞 Get in touch with LeisterTech to schedule your consultation or demo.
Ready to Upgrade Your Foundry's Performance?
If your foundry is still relying on manual lining methods or struggling with early refractory failures, it may be time for a smarter solution. Start with a free audit and let LeisterTech show you how to extend your furnace lining life.
👉 Book your lining audit today
🌐 Visit: leistertech.com
🔍 Browse the full range of furnace tools
📧 Email: [email protected]
📞 Call: +91 93289 16310 / +91 99091 79617
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