Otto Junker has successfully commissioned a medium-frequency induction crucible furnace system of the MONOMELT type for the iron foundry Th. Schultz GmbH & Co. KG in Warendorf, Germany.
The project marks the complete transition of the foundry to an electric melting technology and is part of its transformation plan for decarbonisation and energy efficiency improvement.
With a melting capacity of 1,200 kilowatts and a capacity of 1,700 kilograms of cast iron, the Otto Junker system replaces the cupola furnace and reduces CO₂ emissions in the melting process by around 330 tons per year.
In addition to precise process control, the system enables stable power regulation that can be integrated into existing energy structures.
“The project shows how classic foundry processes can be made sustainable with modern technology – and economically,” said Andreas von Wachtendonk, Regional Sales Manager for Foundry Equipment at Otto Junker.
The plant has been in full operation since February 2025.
Initial practical results from regular operation show that compared to the previous cupola furnace, energy consumption could be reduced by around 50% while at the same time achieving higher process stability and more uniform melting quality.
In addition, workplace comfort has significantly increased due to lower dust and noise emissions.
The conversion required close coordination between Otto Junker and the customer: from the planning and design phase through integration into the existing infrastructure to commissioning and training of operating personnel.