The shift revolves around a patented chip dryer system known as Thermofuge, which is being deployed inside the casting house of one of the company’s auto parts manufacturing sites. The system is not new to the market, wherein 18 units are already operational globally. But what makes this installation noteworthy is the use case of a high-throughput machining setup, with substantial chip volume, and an energy-sensitive cost structure.
Where the traditional thermal dryers apply high heat to eliminate both moisture and residual cutting oils, triggering volatile organic compound (VOC) emissions, environmental compliance costs, and often permitting delays, Thermofuge stops short. Moisture is removed, but oil is left on the chip surface, allowing it to combust in the side-well of the melting furnace. The upshot is a deoxygenated melting environment, which, by design, yields higher aluminium recovery and sidesteps the emissions-intensive drying step.
This selective drying is also what places Thermofuge in a lower regulatory risk category, according to the US Environmental Protection Agency. Its built-in thermal oxidiser handles any incidental emissions, and the waste heat recovery preheats incoming chips.
Financially, the divergence is stark. A traditional chip drying system operating at similar capacity, carries an annual running cost close to USD 150,000, factoring in energy, maintenance, and regulatory controls. Thermofuge, in contrast, operates at around USD 45,000 per year — a roughly 70 per cent reduction. These savings are not just from energy efficiency but also from reduced waste handling, lower labour input, and smaller regulatory footprints.
