Case Study: How a Fully Automated Ingot Casting Line Transformed a Recycling Plant’s Efficiency

Introduction

In the highly competitive recycled aluminum industry, reducing labor costs, ensuring consistent ingot quality, and maximizing operational safety are top priorities. Recently, Nantong Yanbao Intelligent Equipment Co., Ltd. successfully delivered a turnkey automated ingot casting and stacking line to a leading aluminum recycling enterprise.

This case study explores how integrating our advanced automation technology helped the client achieve 24/7 unmanned operation.

The Challenge: Labor-Intensive and Inconsistent

The client, operating a large-scale aluminum recycling facility, was struggling with their traditional casting process:

• High Labor Intensity: Continuous manual pouring, demolding, and stacking required multiple shifts of workers, leading to high labor costs and safety risks.

• Inconsistent Stacking: Manual stacking resulted in uneven pallets, posing challenges for the subsequent storage and transportation of aluminum ingots.

• Low Production Efficiency: Frequent downtime and human errors hindered their goal of continuous, high-volume production.

The Solution: A Turnkey Intelligent Casting System

After an in-depth site assessment, our engineering team designed a fully integrated, end-to-end automated solution. The core of the system included:

1. 20m Chain-Type Ingot Casting Machine: Equipped with an automatic aluminum liquid distributor and frequency conversion speed regulation (up to 3.4m/min), ensuring uniform ingot weight (5kg – 15kg) and a demolding rate of over 99%.

2. FANUC Robotic Palletizing Arm: Replaced the traditional gantry system. This highly sensitive robotic arm performs multi-point grabbing and stacking without the need for a pit foundation, saving valuable workshop space.

3. Automatic Baler: Directly integrated with the stacker to automatically strap the finished ingot stacks securely.

4. Intelligent Warehouse System: Automated forklifts (AGVs) transport the strapped ingots directly to the designated warehouse area.

The Results: 24/7 Unmanned Operation

The implementation of this intelligent line brought immediate and transformative results to the client’s facility:

• Achieved Unmanned Operation: The entire process—from casting to packaging and warehousing—is now fully automated. The plant can run 24 hours a day, 7 days a week, with minimal human intervention.

• Significant Labor Cost Reduction: The client eliminated manual pouring and stacking shifts, redeploying staff to higher-value quality control roles.

• High-Quality Final Products: The robotic stacking ensures extremely neat and aesthetically pleasing ingot stacks, which are highly favored by their downstream buyers.

• Increased Output: With smooth automation and zero human errors, the line achieved a stable production capacity of 15 tons per hour.

Why Choose Yanbao for Your Foundry Automation?

At SmeltPro Market, we partner with industry leaders like Nantong Yanbao to bring cutting-edge thermal and automation solutions to global clients. Whether you need a single reliable casting machine or a fully integrated smart warehouse, our engineering team is ready to tailor a solution to your specific workshop layout and production goals.

Ready to upgrade your foundry? Contact Us Now for a Customized Solution