More than $2 million saved in relining costs after aluminum foundry switches to new refractory

General Aluminum Manufacturing and Metalloy was spending about $175,000 every time it relined its furnaces, typically every other year. By switching to a new refractory material the manufacturer expects to save more than $2 million in total costs associated with the relining program.

Now, the 15 furnaces are being lined with Thermbond, a product of Stellar Materials Inc., Delray Beach, Florida -- and to date there has been no indication that any more relining may be needed. In many cases, these relines have lasted four years with the refractory still performing well.

If each of the 15 furnaces lasts this long before needing another reline (and General Aluminum's facilities manager Jim Muchiarone believes that will happen) it will indicate a savings of $2,625,000 for the Ohio company. In addition to saving money on relining, General Aluminum is recognizing other benefits from the new refractory material. Muchiarone says "Furnaces with the new refractory are easier to clean. They're also more resistant to oxides so there's less build-up on the walls and the floor. The furnaces hold their capacity and have better heat retention as a result."

Established in 1943 in Conneaut, OH, General Aluminum Manufacturing Co. is a subsidiary of Park-Ohio Industries that provides permanent and semi-permanent mold castings to manufacturers in industrial and commercial markets. Automotive manufacturers are core customers, for whom General Aluminum produces parts like transmission pump housings, intake manifolds, planetary pinion carriers, oil filter adapters, clutch retainers, rotor castings, and bearing caps. Its non-automotive parts include as surgical table components, light housings and electrical meter housings.

General Aluminum also performs value-added services like secondary casting, machining, drilling, tapping, and part assembly. Its total annual sales range from $25 million to $50 million.

CLEANING AND MAINTENANCE

General Aluminum/Metalloy has three manufacturing operations in Ohio, another in Indiana, two in Michigan, and one in Mississippi. All of these plants came under General Aluminum's management group when Park-Ohio purchased Metalloy.

Each facility has multiple furnaces, and a wide variety of furnace types and sizes are represented across the company. Many facilities operate gas-fired reverbratory furnaces, and there are also electric furnaces at Conneaut. Several sites have launder and holding furnaces, as well.

Melting capacities range from...