Case Studies

Ageing graphite hot zone suffering from recurring heating element failures, causing repeated production downtime on a critical aerospace vacuum furnace. Temperature uniformity had deteriorated beyond AMS 2750 classification limits.

Complete hot zone redesign with new graphite felt insulation, heating elements, and power feedthroughs. The entire rebuild was engineered and installed during a planned shutdown window, minimising impact on production schedules.

• 15% reduction in energy consumption
• Temperature uniformity improved to ±3°C (AMS 2750 Class 2)
• Zero unplanned downtime in the 12 months following completion

Legacy gas train non-compliant with current IGEM UP/2 standards. Repeated safety check failures were threatening production continuity and creating insurance compliance risk on a gas-fired lead melting furnace.

Installed new Noxmat gas train with Kromschroder BCU 460 burner control unit, dual UV flame detection, and automated valve proving / leak test system. Full BMS replacement with Siemens controller providing automated safety sequences.

• Full IGEM UP/2 compliance achieved
• 12% reduction in gas consumption
• Automated safety sequences with Gas Safe certified installation

Reactive maintenance approach was causing unpredictable downtime on a critical sintering furnace line. Unplanned failures in heating elements, belt tracking, and atmosphere control were disrupting production schedules and threatening CQI-9 compliance.

Implemented a structured preventive maintenance programme: monthly atmosphere checks, quarterly element resistance mapping, 6-monthly roller and belt inspections, and annual Temperature Uniformity Surveys (TUS). All work documented to support CQI-9 audit requirements.

• 40% reduction in unplanned downtime
• Extended belt life by 18 months beyond expected replacement
• Maintained full CQI-9 compliance through all audits

Critical heat exchanger failure on an annealing furnace brought production to a standstill. The OEM quoted a 16-week lead time for a replacement unit, which was unacceptable for ongoing production commitments.

Reverse-engineered the failed unit on site, designed an improved replacement in 316L stainless steel with an optimised baffle design for better heat transfer. Fabricated in our workshop and pressure tested to 10 bar before delivery and installation.

• Furnace back online in 8 days vs 16-week OEM lead time
• Improved thermal efficiency from optimised baffle design
• 3-year warranty on the replacement unit