Boro’ Foundry cuts induction furnace cooling costs with Meltech control system

Boro’ Foundry has upgraded its induction furnace cooling process with Meltech, replacing a fixed post-production run time with demand-led PLC control. The change cuts daily runtime by 5.5 hours, saves an estimated £5,448 a year and is expected to pay back in about 2.45 years.

Why it matters: - Boro’ Foundry says the upgrade reduces electricity use on a high-energy industrial process. - The shorter run time also reduces wear on pumps, motors and fans. - The project supports the foundry’s sustainability goals without requiring a major equipment replacement.

What happened: - Boro’ Foundry partnered with induction furnace technology specialist Meltech to modernise cooling operations at its West Midlands site. - The foundry moved from a fixed six-hour cooling run-on after production to an intelligent, demand-led PLC control system. - The new setup uses real-time communication between a PLC system and a Pulsar IGBT inverter. - The control system adjusts cooling activity based on actual temperature needs.

The details: - Induction melting systems depend on circulating water-cooling pumps and external fans to protect equipment. - The old process kept cooling equipment running at full capacity even when demand was lower. - The upgraded system automatically shuts down once optimal cooling is reached. - Cooling pump and fan runtime has fallen from 6 hours to 30 minutes after production. - The change saves 5.5 hours of energy use on every operating day. - Boro’ Foundry estimates the project will save £5,448 a year. - The system is expected to reach full payback in about 2.45 years.

Between the lines: - The project shows how industrial energy savings can come from control upgrades rather than new plant. - For heavy manufacturers, trimming idle runtime can deliver both utility savings and lower maintenance costs. - Sam Edwards, sales director at Boro’ Foundry, said efficiency gains can come from making smarter use of existing systems rather than major capital investment.

What's next: - Boro’ Foundry says the modernisation fits its broader commitment to sustainable manufacturing and continuous operational improvement. - The company points to its engineering capabilities and sustainability initiatives in a full case study for more information.