The above involves focus on helping to improve our customers’ process capability, process efficiency and environmental compliance.  We describe this function as providing ‘EVC’, the letters meaning ‘Economic Value to the Customer’. 

Here's how we have helped some of our customers meet specific challenges.

Case Study 2

Reducing costs in fan head production
Our engineers put our products to work to help a European foundry achieve major reductions in production and cleaning costs during the production of nickel/chromium fan heads. Using our in-depth knowledge of the customers’ foundry processes, we suggested the introduction of a modified feeding and gating system and our KALPUR ST direct pour system.

EVC - The benefits, assessed by the United Kingdom Government’s Department of the Environment’s Energy Best Practice programme, showed a £20 saving for a cost of £5 per fan head. As an added bonus, the foundry has been able to decrease its cleaning costs.

Case Study 3


Improved quality plus lower costs for iron foundry
Our KALTEK cold ladle lining system has delivered a host of cost and quality benefits to a French SG iron foundry. By combining efficient insulation with refractory stability, KALTEK systems have resulted in improved metal quality while lowering energy, cleaning and refractory costs.


EVC - The foundry achieved a saving of €52,600 per annum for a cost of €9150. Lower furnace temperatures have secured major energy savings and the metal quality has also been improved through the reduction of refractory inclusions. In addition, the company has benefited from improved safety and working conditions, while lowering its costs for pollution control equipment.

Case Study 4


Delivering scrap and energy savings
Our products and services were instrumental in helping a non-ferrous foundry cut scrap rates and improve productivity in the production of aluminium engine sumps. The solution involved a redesign of the runner system and the introduction of the SIVEX filters. The benefits, assessed by the United Kingdom Government’s Department of the Environment’s Energy Best Practice programme, included higher productivity and a 3.5% reduction in scrap rates.


EVC - Overall, the foundry has gained a £3.62 saving per engine sump casting.

Case Study 5

Achieving cleaner metal and lower energy costs
Introduction of our INSURAL ATL ladle liner product delivered a significant quality and cost advantage to an aluminium gravity die foundry in Europe.


EVC - By using the INSURAL ATL ladle liner in its processes, the operation has achieved a 90% reduction in gas consumption. The process now requires lower melt temperatures, while casting quality has also been improved because of the cleaner metal. The business has gained a saving per ladle of £1,858 per annum.


Case Study 6

Creating a safer, cleaner environment
Our products have significantly reduced emissions at a leading aluminium foundry and made the fluxing process safer and cleaner.


EVC - The introduction of our COVERAL GR flux product has achieved a 50% reduction in gaseous chlorine emissions from the plant, plus a 75% reduction in fluorine, nitrogen and sulphur oxides. The benefits include a greatly improved working environment and lower capital investment costs for pollution control equipment.

Case Study 7

To improve casting quality, raise productivity and reduce costs at a European non-ferrous foundry, Foseco proposed a redesigned runner system and introduction of our KALPUR NF direct pouring product.


EVC - The foundry produces conveyor hanger castings and has now been able to achieve higher quality castings - particularly important with this safety critical component. A 75% reduction in scrap rate and higher productivity has also been gained, with costs reduced by US$6.83 per hanger.

Case Study 8

Using Foseco expertise to increase productivity
Our expertise and technical excellence proved invaluable to a non-ferrous foundry producing aluminium air intake manifolds. We carried out analysis of the foundry’s existing practice using our CAD modelling program and fluid flow simulation software. As a result, the foundry’s running, pouring and gating system was redesigned as a result, and SIVEX filters introduced.

EVC - Productivity has increased and the customer has gained a saving of US$2.67 per manifold.