The Polish die-casting foundry LENAAL increases production availability by up to 50 per cent with Monitizer | REFILL MONITOR
Automated refill monitoring for maximum efficiency
REFILL MONITOR is compatible with all standard holding and dosing furnaces. The system continuously monitors the fill level of the dosing furnaces and synchronises it with metal consumption in the die-casting process. It provides precise, real-time information on when refilling is required, which alloy is needed and what the optimum metal weight is. This helps to avoid downtime and ensure a smooth production process.
From the test phase to successful implementation
Following a successful pilot project in 2023, LENAAL has gradually extended the digital furnace monitoring system to further production lines. Combined with the investment in two additional casting cells, equipped with new Westomat dosing furnaces from StrikoWestofen, production output has been increased by 65 per cent.
All 13 Westomat furnaces, as well as the fully automatic horizontal cold-chamber die-casting cells they supply, are now integrated into the digital monitoring system – a further step towards greater efficiency and transparency in production. LENAAL is already convinced by the results.
Production availability increased by up to 50%
Previously, operators had to check each furnace manually – a time-consuming process that occasionally led to empty furnaces and, consequently, production stoppages.
“We no longer have this problem. Thanks to REFILL MONITOR, we have been able to increase production availability by 25–50 per cent,” explains LENAAL process engineer Jakub Pomajda.
More efficient day-to-day operations
In addition to the dashboards for monitoring fill levels, the smelting department team also uses the system to analyse and optimise key performance indicators such as furnace temperatures, completed dosing cycles and the average metal dosage per cycle.
“I am absolutely delighted with REFILL MONITOR – it has noticeably improved our operations,” says Jakub Pomajda. “The best thing about it is how easy it is to use. As an engineer, I have all the relevant data for my daily tasks in a clearly laid-out dashboard, so I can produce reports quickly and accurately. It’s ideal for a busy die-casting foundry like ours.”