Industry: Medium-Scale Steel Foundry
Location: Ahmedabad, Gujarat
Furnace Capacity: 3-ton Induction Furnace
Challenge: Frequent Lining Failures Every 18–20 Heats
Solution: LeisterTech Lining Vibrator – Model X
In this case study, we dive into a real foundry’s production challenges and how switching to a mechanical lining vibrator helped them extend lining life, reduce material waste, and save nearly ₹6,00,000 annually.
This Ahmedabad-based steel foundry operated a 3-ton induction furnace, producing alloy castings for the auto industry. Their team relied on manual ramming to install high-alumina refractory linings.
Despite using quality refractory material, the lining regularly failed after just 18 to 20 heats.
Key Issues Identified:
- Uneven compaction in lower crucible
- Manual fatigue leading to inconsistent ramming
- Visible cracks after just 12–14 heats
- Lining failure led to 3–4 days of downtime/month
The Intervention – Installing a Lining Vibrator
After a free technical audit by LeisterTech’s engineering team, the foundry installed a LeisterTech Model X Lining Vibrator, custom-calibrated for their furnace size and refractory mix.
Customizations Included:
- Adjustable RPM: 2200–2800
- Wide vibration head to cover larger crucible radius
- Reinforced base for portability
- Operator training by LeisterTech engineers
Explore the Model X specs here
Results (Within 60 Days)
Metric | Before | After LeisterTech Vibrator |
Lining Lifespan | 18–20 heats | 29–32 heats |
Monthly Downtime | 3–4 days | <1 day |
Refractory Material Waste | 12% per batch | <5% per batch |
Operator Fatigue | High | Low (semi-automated) |
Annual Maintenance Cost | ₹8.5 lakhs | ₹2.4 lakhs |
Key Takeaways
- Consistent compaction means fewer voids, cracks, and lining erosion.
- Vibrators reduce dependency on operator skill.
- Upgrading your lining process doesn’t require large automation investment – just smart tools.
- Custom vibrators can be adapted to any furnace size or lining material.
🔗 Check out our furnace-specific vibrator range: leistertech.com/product/lining-vibrators
Bonus: Our Support Doesn’t End at Installation
We provide:
- On-site vibration demo and training
- Vibrators reduce dependency on operator skill.
- Annual servicing and upgrades
Ready to Upgrade Your Furnace Efficiency?
Let’s solve your lining challenges—just like we did for this foundry.
📞 +91 93289 16310 / +91 99091 79617
✉️ Email: info@leistertech.com
🌐 Visit: leistertech.com/contact-us
