Pier Foundry has achieved a new level of efficiency and productivity thanks to an innovative addition to its melt shop. In November 2023, the Minnesota foundry installed a five-ton furnace and the second half of its VIP® Dual-Trak® power supply unit, finally completing its objective to increase output by 30%. This upgrade is part of the ferrous foundry’s thoroughly planned, long-term expansion strategy to maximize casting output.
The foundry did not initially invest in the full VIP® Dual-Trak® unit, with its alternating power capabilities. Instead, it purchased half of it—the VIP® Dual-Trak® Ready, which includes the 3,000 kW power supply that could connect to a single furnace, otherwise known as the VIP® Power-Trak®. However, this power supply was “ready” to be upgraded with its second half, once Pier Foundry decided it was ready for that step.
For Pier Foundry, this meant seamless integration of the new five-ton furnace with the existing VIP® Dual-Trak® Ready unit, even though that had been installed in 2012. The plug-and-play compatibility of the power system ensured a smooth transition to a full VIP® Dual-Trak® power supply unit, so the foundry could meet rising product demand with minimal downtime.
The result? Just over a year later Pier Foundry produces an impressive amount of finished castings each month. It’s an impressive achievement driven largely by the enhanced melt capacity the full VIP® Dual-Trak® power supply unit provides.
A powerhouse of efficiency
Inductotherm’s VIP® Dual-Trak® system is a game-changer for continued innovation in induction heating and melting. Designed with flexibility, scalability, and efficiency in mind, this advanced technology offers foundries the ability to adapt and grow without extensive—and expensive—infrastructure changes. The modular design of Inductotherm’s line of Multi-Output™ systems typically consolidates the capacity of multiple power units into a larger power output. This saves valuable shop floor space and minimizes investment costs for each ton of metal produced.
Another key operational benefit is that it allows equipment utilization approaching 100%, to melt more metal in less time with less power. Foundries know they are able to do more with less, and achieve greater success with long-term investment purchases.
Since VIP® Dual-Trak® power supply units allow for the same amount of power to be distributed between two furnaces, foundries like Pier Foundry can be sure that they are getting the maximum productivity from of the equipment—whether it’s a 50/50 split or one furnace melting as the other is pouring.
A legacy of collaboration
Pier Foundry’s partnership with Inductotherm spans four decades, a relationship defined by shared goals of growth and innovation. This began in 1980 when Pier Foundry replaced a cupola furnace with an Inductotherm induction furnace, revolutionizing its ferrous metal melting process. For 32 years, this furnace was the backbone of the operation, delivering efficient and reliable results.
When Pier Foundry installed a five-ton Inductotherm furnace paired with a 3,000 kW VIP® Dual-Trak® Ready power supply unit in 2012, this was yet another leap forward. This strategic move not only expanded the casting capabilities and laid the groundwork for future growth in their furnace line, as these systems are designed to easily expand when production demands increase.
The 2023 installation marked another milestone in the long-term partnership. With the addition of a new five-ton furnace, Pier Foundry further cemented its position as a metalcasting leader. By leveraging the scalability of Inductotherm’s systems, they achieved a 30% increase in melt capacity without requiring additional power infrastructure. One year later, their furnace remains powered by the VIP® Dual-Trak® unit and continues its expected output.
Planning the future
Pier Foundry isn’t stopping here. Building on its success, the current plan is to expand the power supply capabilities and automate the charge system to achieve full power utilization. With Inductotherm as a partner, Pier Foundry is well-positioned to continue growing, and prospering.
This partnership is a testament to the power of long-term collaboration and advanced technology to deliver industry-leading results. And as Pier Foundry shows, combining strategic planning with cutting-edge equipment can unlock new levels of productivity and efficiency.