Over 60 years’ experience at FOMET

With more than six decades of technical expertise, FOMET SRL has established itself worldwide as a benchmark in the development and manufacture of induction melting technology. The company is particularly well known for its BB-type channel induction furnaces with a double-chamber design, which were developed specifically for melting brass.

These furnace systems are widely valued for their long service life and reliability. At a foundry in the United Kingdom, the power control system – originally installed in the 1970s – was only recently replaced, after decades of operation. Thanks to comprehensive modernisation measures, several furnace frames have been in continuous operation for over half a century. The refractory linings typically have a service life of over five years; they often last longer than ten years and, in exceptional cases, can even reach a service life of up to fifteen years.

FOMET offers support for a variety of production environments

FOMET’s BB furnaces are designed to support a wide range of production environments – from manual die-casting to fully automated casting processes. Both the melting and holding chambers can be individually configured to integrate seamlessly into automated loading, handling and unloading systems.

Equipped with a proprietary air-cooling system, FOMET’s twin-chamber channel induction furnaces are optimised for the melting and temperature control of brass alloys. These alloys are used in the manufacture of fittings, sanitary components, water meters, valves and various precision brass products. The systems efficiently process both conventional copper alloys and advanced special alloys – including lead-free and lead-containing materials with alloying elements such as zinc, silicon, aluminium and phosphorus.

Performance data:

• Power: 65–250 kW
• Capacity: 1,000–2,500 kg
• Melting capacity: 220–1,000 kg/h
• Energy consumption: approx. 190–270 kWh/t

FOMET “Type BB” offers cost-effectiveness and quality in die-casting

Twin-chamber channel induction furnaces for melting and holding brass alloys at temperature

The furnace operates as a stationary unit comprising two separate yet integrated chambers: a dedicated melting chamber and a holding zone. Both areas are connected by inductively heated channels, which enable continuous metal circulation. This configuration ensures that the melting capacity is automatically adjusted to the withdrawal rate from the holding bath, whilst also enabling precise and stable temperature control throughout the entire process.

The system achieves outstanding energy efficiency through the direct conversion of electrical energy into thermal energy. Its air-cooled induction technology generates heat directly within the molten metal, thereby enabling constant heating at optimum operating temperatures – always within the load limits of the refractory lining materials.

FOMET dual-chamber furnaces are designed for use in a wide range of casting processes – including high-pressure die casting, low-pressure die-casting and permanent mould casting – and contribute significantly to increased production efficiency, improved casting quality and a significant reduction in total operating costs.

The 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, consisting of the charging chamber, the pouring chamber and two or three parallel induction channels. One or two primary induction coils, coupled via layered iron core assemblies, generate an electromagnetic field that induces a current flow within this metal circuit. The induction coils are cooled by forced air circulation provided by a fan mounted directly on the furnace frame.

Technical data:

• Power range: 65–250 kW
• Capacity: 1,000–2,500 kg
• Frequency: 50–60 Hz
• Voltage: 400 or 440 V (others on request)
• Energy consumption: decreases with increasing power from approx. 270 to 190 kWh/t

The furnaces are suitable for use with ladle systems as well as for direct casting into die-casting machines or permanent moulds.

FOMET twin-chamber furnaces and their advantages

Extremely durable refractory lining

The specially developed refractory lining has been specifically designed to withstand both thermal shocks and aggressive chemical environments, resulting in an extended service life. Under continuous production conditions, the service life typically ranges from four to six years. The furnace can be returned to service without structural damage or cracking; furthermore, the relining process is straightforward, quick and cost-effective.

Improved working conditions and cost-efficiency

The equipment contributes to noticeably improved workplace conditions through the following features:

• minimised exposure to radiant heat
• reduced operating noise
• elimination of smoke and harmful emissions
• full compliance with applicable safety regulations and international industry standards, including IEC requirements

High-precision temperature control
The casting temperature remains stable regardless of fluctuations occurring in the melting chamber. This constant thermal control limits slag formation and significantly reduces evaporation losses of volatile alloying elements such as zinc.

2-in-1 furnaces

Melting and holding functions are integrated into a single compact system, eliminating the need for separate installations. This integration reduces maintenance requirements and minimises production downtime. Production scrap and return material can be remelted efficiently and safely within the same unit.

Optimised metallurgical control
Electromagnetic circulation promotes a uniform metal composition and reduces the occurrence of non-metallic inclusions. Flux consumption is significantly reduced, oxide formation is minimised, gas absorption is limited and overall casting performance is enhanced.

Minimisation of metal losses
Thermal energy is generated directly within the molten metal, which greatly limits oxidation processes. As no combustion takes place, no flue gases are produced, and material losses associated with metal transfer are eliminated.

Efficient use of resources

• Reduced maintenance requirements compared to combustion-based furnaces
• Space-saving design with efficient integration into the plant layout
• Suitable for advanced automation concepts
• Automatic preheating before production begins
• Energy-efficient hold mode during overnight or at weekends with minimal heat loss

From an economic perspective, FOMET BB furnaces offer:

• Reduction in scrap generation
• Highly efficient production processes
• Optimised energy use
• Lower maintenance and operating costs

Thanks to the reduced cost per kilogramme of finished castings, payback periods are generally short.

The key advantages of FOMET BB furnaces:

• Low energy consumption
• Efficient use of resources
• High metal quality
• Industry 4.0 compatibility
• Minimal melting losses
• Improved environmental footprint

These furnaces enable cost-effective, environmentally friendly and high-performance foundry production that fully meets the requirements of modern, energy-efficient manufacturing as well as the principles of the circular economy.