With more than six decades of engineering expertise, FOMET SRL has established itself as a worldwide reference in the design and production of induction melting technology. The company is particularly known for its BB-type twin-chamber channel induction furnaces developed for brass melting applications.
These furnace systems are widely appreciated for their long operational lifespan and reliability. At a foundry in the United Kingdom, original power control equipment installed in the 1970s has only recently been replaced after decades of service. Following modernization upgrades, several furnace structures have remained in continuous operation for over half a century. Refractory linings typically deliver service periods exceeding five years, frequently lasting more than ten years and, in exceptional cases, reaching up to fifteen years.
FOMET Offers Support for Different Production Environments
FOMET BB furnaces are designed to support a broad range of production environments, including manual gravity die casting as well as fully automated die-casting processes. Both melting and holding chambers can be individually configured to integrate seamlessly with automated charging, handling, and discharge systems.
Equipped with a proprietary air-cooling concept, FOMET twin-chamber channel induction furnaces are optimized for melting and temperature control of brass alloys used in the manufacture of faucets, sanitary components, water meters, valves, and various precision brass products. The systems efficiently process conventional copper alloys alongside advanced specialty compositions, including lead-free and lead-containing materials with alloying elements such as zinc, silicon, aluminum, and phosphorus.
Performance Data:
- Power: 65–250 kW
- Capacity: 1,000–2,500 kg
- Melting rate: 220–1,000 kg/h
- Energy consumption: approx. 190–270 kWh/t
FOMET “Type BB” offers Profitability and Quality in Die Casting
Twin-Chamber Channel Induction Furnaces for Melting and Holding Brass Alloys
The furnace operates as a fixed installation featuring two separate but integrated chambers: a dedicated melting chamber and a holding chamber. Both sections are connected through induction-heated channels that allow continuous metal circulation. This configuration ensures that melting capacity automatically matches the consumption rate of the holding bath while enabling accurate and stable temperature regulation throughout the process.
The system achieves outstanding energy performance through the direct transformation of electrical power into thermal energy. Its air-cooled induction technology generates heat directly inside the molten metal, allowing constant heating at optimal operating temperatures within the resistance limits of the refractory lining materials.
Designed to support a wide range of casting technologies—including high-pressure die casting, low-pressure casting, and gravity die casting—FOMET twin-chamber furnaces contribute to higher production efficiency, improved casting consistency, and significant reductions in total operating expenses.
Operating Principle
The operating principle of the system is comparable to that of an electrical transformer. The molten metal itself forms a closed secondary circuit, created by the charging chamber, the pouring chamber, and two or three parallel induction channels. One or two primary induction coils, coupled through laminated iron-core assemblies, generate an electromagnetic field that induces current flow within this metal circuit. Cooling of the induction coils is achieved through forced air circulation supplied by a blower installed directly on the furnace structure.
Technical Data:
- Power range: 65–250 kW
- Capacity: 1,000–2,500 kg
- Frequency: 50–60 Hz
- Voltage: 400 or 440 V (others available)
- Energy consumption: decreases from approx. 270 to 190 kWh/t with increasing power
The furnaces can be used with ladle systems as well as for direct pouring into die casting machines or permanent molds.
FOMET Twin-Chamber Furnaces and Their Competitive Advantages
Extremely Durable Refractory Lining
The engineered refractory lining has been specifically formulated to withstand both thermal shock and aggressive chemical environments, resulting in extended operational durability. Under continuous production conditions, service life typically reaches four to six years. The furnace can be restarted without structural damage or cracking, and relining procedures are straightforward, fast, and economical.
Improved Working Conditions and Cost Efficiency
The equipment contributes to noticeably improved workplace conditions through:
- minimized radiant heat exposure
- reduced operational noise
- elimination of smoke and harmful emissions
- full conformity with applicable safety regulations and international industry standards, including IEC requirements
High-Precision Temperature Control
The pouring temperature remains stable regardless of variations occurring in the melting chamber. This consistent thermal control limits dross generation and significantly reduces evaporation losses of volatile alloying elements such as zinc.
Two-In-One Furnaces
Melting and holding functions are integrated within one compact system, eliminating the need for separate installations. This integration lowers maintenance requirements and reduces production interruptions. Production scrap and return material can be remelted efficiently and safely within the same unit.
Optimized Metallurgical Control
Electromagnetic circulation promotes uniform metal composition and decreases the presence of non-metallic inclusions. Flux consumption is substantially reduced, oxide formation is minimized, gas absorption is limited, and overall casting performance is enhanced.
Minimization Of Metal Losses
Thermal energy is generated directly inside the molten metal, which greatly limits oxidation processes. Since combustion is not involved, no flue gases are produced and material losses associated with metal transfer are eliminated.
Efficient Use of Resources
- reduced maintenance requirements compared with combustion-based furnaces
- space-saving construction with efficient plant layout integration
- suitability for advanced automation concepts
- automatic preheating prior to production start-up
- energy-efficient holding operation during nights or weekends with minimal heat loss
From an economic perspective, FOMET BB furnaces offer:
- decreased scrap generation
- highly efficient production processes
- optimized energy usage
- lower servicing and operational expenses
Thanks to the reduced cost per kilogram of finished castings, investment payback periods are generally short.
Key Benefits of FOMET BB Furnaces:
- low energy consumption
- efficient use of resources
- high metal quality
- industry 4.0 compatibility
- minimal melting losses
- improved environmental performance
These systems support cost-efficient, environmentally responsible, and high-output foundry production, fully meeting the demands of modern energy-efficient manufacturing and circular economy principles.
