1. Project background: sensitive aluminum prices, unstable ingot output

This Russian scrap aluminum recycling company mainly collects scrap from car dismantling and machining shops, melts it, and sells aluminum ingots to local aluminum die casting plants and export customers. However, their original small casting line had several serious weaknesses:

• Unstable hourly output – manual pouring and a short casting line made the real capacity fluctuate a lot, especially under rush orders.

• Non-standard ingot sizes – different molds and inconsistent pouring caused size variation, which made stacking, palletizing and container loading inefficient.

• Insufficient cooling and internal stress issues – because the line was short and cooling was not well controlled, some ingots showed surface shrinkage and hidden internal stress, and die casting customers were not fully satisfied.

The management wanted a standardized 9m Aluminum Ingot Casting Machine line that could stabilize 2–3 tons per hour and produce ingots that meet both the Russian market and export packaging standards.

2. Solution: 9m Aluminum Ingot Casting Machine with 2–3t/h continuous casting

Based on the customer’s furnace capacity and plant layout, we supplied a 9m Aluminum Ingot Machine / Aluminum Ingot Casting Machine as a complete casting line:

• 2–3 tons per hour design capacity
  The line was engineered for a continuous casting rate of 2–3t/h, matched to the output of the existing melting and holding furnaces. This avoids situations where the furnace is waiting for the line or the line is waiting for molten metal, making production planning and shift assessment much easier.

• Ingot molds customized to Russian die casting habits
  Mold dimensions were designed according to sizes commonly used by Russian aluminum die casting plants. This makes it easier for their automatic de-palletizing and charging systems, and at the same time helps the recycler create standard pallets with higher storage and container loading efficiency.

• Automated pouring, cooling, de-molding and ingot flipping
  The 9m ingot casting machine handles automatic pouring, vibration cooling, de-molding and flipping of ingots. Operators mainly supervise and handle strapping/packing instead of doing heavy manual pouring. For Russian companies facing rising labor costs and a shortage of skilled furnace operators, this reduction in manual dependence is a major advantage.

3. Results: from “scrap collector” to “stable aluminum ingot supplier”

After commissioning, the Russian customer saw clear benefits:

• Stable 2–3t/h output of standard ingots – they can now commit to more long-term contracts without frequently pushing back delivery dates due to unstable capacity.

• Uniform ingot size and neat stacking – pallets are cleaner, container loading is faster, and the company has a stronger position when negotiating with local and export buyers.

• Business role upgrade – instead of being seen only as a scrap collector, the company is increasingly recognized as a “reliable aluminum ingot supplier” in the local aluminum die casting supply chain.