Furnace Charger
A vibrating furnace charger is a heavy-duty material handling unit that mechanically and safely delivers scrap, sponge iron, ferro-alloys, or other charge material into induction furnaces, electric arc furnaces, or rotary melting furnaces. By eliminating manual scrap charging, Mitool's furnace chargers solve the three biggest problems faced in foundries and steel mills: high labour cost, severe burn-and-splash hazards to operators, and inconsistent charging cycle times that hurt furnace productivity.
Designed for foundries, steel mills, ferro-alloy plants, and non-ferrous melting operations, Mitool's furnace chargers are engineered around the actual furnace mouth dimensions, charge mix, and shop floor layout of each client — a custom approach that off-the-shelf machines from generic suppliers cannot match.
Working principle
Scrap or charge material is loaded into a heavy-walled steel trough mounted on the charger. When the charge cycle is triggered, twin unbalance vibrating motors generate a powerful linear vibration that propels the material forward, along the trough, and into the furnace mouth.
Construction and features
- Heavy-gauge trough: Hardox or wear-resistant steel lining, reinforced base, capable of handling jagged scrap without deformation
- Drive: twin unbalance vibrating motors, sized for the trough mass plus full scrap load
- Frame: fabricated from heavy I-beam and channel sections, stress-relieved before machining
- Spring isolation: compression springs prevent vibration transmission to the shop floor
- Control panel: push-button or PLC-controlled cycle, with operator station located safely away from the furnace mouth
- Mobile option: trolley-mounted variants on rails or wheels, for serving multiple furnaces from a single charger
Furnace charger specifications
| Parameter | Range |
|---|---|
| Charge capacity | 500 kg – 10,000 kg (per cycle) |
| Trough length | 1500 mm – 6000 mm |
| Trough width | 600 mm – 1800 mm |
| Cycle time | 30 – 90 seconds (typical) |
| Drive | Twin heavy-duty unbalance vibrating motors |
| Trough material | Hardox 400 / 500 / wear-resistant MS with replaceable liners |
| Mobile option | Trolley-mounted on rails or floor wheels |
| Control | Local push-button / remote pendant / PLC-integrated |
| Power supply | 415 V, 3-phase, 50 Hz |
Industries & applications
- Foundries: iron, steel and non-ferrous casting shops — feeding induction furnaces with scrap, returns, and alloying additions
- Steel mills: electric arc furnaces, induction furnaces
- Ferro-alloy plants: charging silicon, manganese, chrome alloys
- Non-ferrous melting: aluminium, copper, brass, zinc — typically lighter-duty trough designs
- Recycling: scrap metal recycling plants for controlled, mechanised charging
Benefits over manual scrap charging
- Operator safety: no more workers near the furnace mouth during charging — eliminates burn, splash, and ejecta hazards
- Faster cycle: consistent 30–90 second discharge versus 3–5 minutes for manual charging
- Higher furnace productivity: more melts per shift, more output per kWh
- Reduced labour cost: one operator runs the charger versus a team of manual chargers
- Better refractory life: controlled, gentle charging avoids the impact damage caused by manual scrap drop
Why choose Mitool's furnace chargers
- Custom-engineered to your furnace: trough dimensions sized to your furnace mouth, capacity matched to your melt size
- Heavy-duty for scrap abuse: Hardox liners or replaceable wear plates, reinforced trough construction
- Robust drive system: Mitool's own vibrating motors with full centrifugal-load bearings
- Safe operator station: pendant or remote control means operator can stand clear of the furnace
- Pan-India + export installations: deployed in foundries across Maharashtra, Gujarat, Tamil Nadu, Karnataka, and exported to Middle East and South-East Asia
Frequently Asked Questions
A. Match the charger trough capacity to your furnace's per-melt charge requirement, with around 10% spare for safety. For example, a 3-tonne induction furnace typically uses a 3.3-tonne capacity charger. Mitool engineers will confirm sizing once you share your furnace specifications.
A. Yes — a trolley-mounted, rail-traversing charger can shuttle between two or more furnaces. This is a common configuration in foundries with parallel melting bays.
A. Standard troughs are lined with Hardox 400 or 500 wear plate, replaceable when worn. For severely abrasive charge mixes such as sand-coated returns, thicker replaceable liners can be specified.
A. Yes — the trough and motors are designed to withstand radiant heat. Splash guards and heat shields are added when the unit operates within 1.5 m of an open furnace bath.
A. Standard capacities ship in 8–10 weeks. Custom mobile or PLC-integrated versions take 10–14 weeks. Layout drawings are issued within 2 weeks of order confirmation for client approval.
