The Schaefer Group, Inc.

100% CUSTOM DESIGNED FURNACES & SYSTEMS

Since 1970, The Schaefer Group has developed custom aluminum furnaces for die casting, permanent mold and sand foundries. We specialize in electric, gas, and propane as well as combination fuel furnaces for melting, holding and transfer.

We also custom design launder systems, crucibles, filtration and degassing systems.

Our re-line and repair services can retrofit existing furnaces as well. We have probably custom designed more molten metal delivery systems than anyone else in the world. Over 50 years of experience makes Schaefer Furnaces the experts in Profitably Casting Your Bottom Line!

ADVANTAGES:
- Custom Furnaces – that melt sows, ingots, and chips all in one furnace.
- Custom Smaller Furnaces – including holding furnaces, crucibles and low pressure units.
OPTIONS:

Available options depending upon the furnace size are:
- Alarm thermocouples
- Filter silencers on blowers
- Flue pressurization systems
- Circulation and transfer pumps
- Premium lining materials
- Super insulated linings
- Walkways and hand rails on larger furnaces
- Individual burner controls
- PLC and HMI capabilities
- SCADA control data collection
- Filtration
- Degassing
- Heat pipe heat exchangers
- Idec displays
Electric Aluminum Melting Furnaces

The Schaefer Group developed the world’s first electric reverbatory (wet bath) furnace in 1974 and the rest is history. This furnace is now the industry’s first choice for low cost production of clean molten aluminum. Our highly efficient electric reverberatory melting furnaces provide the best quality metal from ingot or scrap. And, they have an extremely low metal melt loss and are easy to operate and maintain. Melt loss is so low with this furnace (often less than 1%) that those savings alone typically provides a one year (or less) return on investment!

ADVANTAGES:
- Excellent Metal Quality – no combustion means no metal gassing and a conservatively-sized tranquil bath eliminates oxide-creating metal turbulence.
- Melting – silicon carbide resistance elements transfer radiant heat to the work load to melt metal with only 0.20 to 0.23 KWH per pound. You can even melt efficiently from a cold start. A full-proportioning control system delivers accurate energy flow.
- Melt loss – typically less than 1%.
- Cleaner heat – means a cleaner work space.
- Sustainability – no output of hot fuel gasses to heat up the environment means reduced carbon footprint.
OPTIONS:
- Alarm thermocouples
- Premium lining materials
- Super insulated linings
- SCADA control data collection
- Filtration
- Degassing
- Electric meters
Ultra Low Energy (Gas/Electric) Holding Furnaces

Electric Holding Furnaces
A 2,000 pound (907.2 kg) Schaefer electric holding furnace will maintain a temperature of 1,300 degrees Fahrenheit (704.4 degrees Celsius) for only 3 KW/hr (2,581.2 kcal/hr) with well covers. Similar savings can be achieved with all capacities ranging from 1,500 (680.4 kg) to 30,000 pounds (13607.77 kg).

Gas Holding Furnaces
A 2,000 pound (907.2 kg) Schaefer gas holding furnace will maintain a temperature of 1,300 degrees Fahrenheit (705 degrees Celsius) with 50 to 60 CF gas/hr (12,660-to-15,120 kcal/hr). We can also supply a dual energy option that lets you convert between electricity and gas to use the lowest cost source.

ADVANTAGES:
- Efficient holding of temperatures at low cost.
- Easily cleaned.
- Very little pick up of hydrogen in our gas fired units.
- Full proportioning controls means we connect more than you will ever need, but use only what it takes to maintain temperature!
OPTIONS:
- Power-operated tilt lid allows cleaning of the furnace in less than 10 minutes.
- Full-proportioning with solid-state microprocessor controls and specially-designed heating elements with a proven record of superior service life can be easily added.
- Alarm thermocouples
- Filtration
- Degassing with T Wands
- Molten Metal Circulation
- Inoculation
- Rotary Degassing
Gas, Oil or Propane Aluminum Furnaces

For fuel efficiency like no other; gas, oil or propane aluminum furnaces by The Schaefer Group hit the mark. Typical melting efficiency, based on 100% cold charging with an exterior charge well, is 1,500 BTU of gas per pound (378 kcal/0.4536 kg) of metal in a Schaefer furnace radiant roof-fired reverb. Whatever the fuel, this is only 1,500 BTU per pound (378 kcal/0.4536 kg). And, if you preheat at least 50% of the metal charged in the form of ingot or sows, the number drops to 1,200 BTU of gas per pound (302.4 kcal/0.4536 kg). Batch-type melting reverbs are also available with the latest in high velocity burners.

ADVANTAGES:
- Clean Metal – non-wetting refractory linings will not contaminate the metal.
- Excellent Temperature Control – Filtration is optional.
- Clean Furnace – all blind corners are eliminated and door jambs are tangent with the walls for full accessibility. A clean-out-door provides easy access to the hearth and allows easy clean-up of the furnace bottom or to skim the bath.
- Liquid Metal Deliveries – Schaefer reverbs can be engineered with large holding capacities that offer enough “draw-down” capability to accept molten metal delivery.
- Regeneration & Recuperation (explained under Operation & Maintenance) – improve melting efficiency even more by preheating the ambient air and metal through a combination of pre-heat hearths, regeneration and recuperation. Melt rates of 950-to-1,000 BTU/lb (239.4-to-252 kcal/0.4536 kg) can be obtained with the right combination of equipment.
OPTIONS:
- Circulation wells and molten metal pumps provide rapid heat transfer from the furnace to the pump and charge wells and back again. This is particularly effective when melting chips from machining operations as circulation breaks the surface tension, pulls the chips down into the melt immediately and keeps the bath homogenized. The Schaefer furnace design uniquely minimizes heat loss.
High Performing Stack/Tower Melters

For the past several years, we have been developing a Stack Melter that would exceed our customer’s melting expectations and our high reliability standards and are now pleased to bring this to market.

Significant Stack Melter Advantages:
- Reduce Metal Lost – higher yields up to 98%
- Simple Operation – easier to maintain
- Compact – uses 1/3 of conventional space
- Reduce Energy – savings up to 25%
- Environmental Friendly – less exhaust, chips & scattering
Molten Metal Launder Systems

The most technically advanced way to deliver molten aluminum from melting furnaces to holders and die casting machines is in a heated launder system. A launder minimizes turbulence and oxides in the molten metal and because the metal flows in a quiet stream to the holding furnace, it eliminates transfer labor and monorails, fork trucks, and bull ladles. It automatically delivers the exact amount of metal you need – on-time and at temperature. Launder systems aren’t the answer for everyone. They must be carefully considered because they can reduce the flexibility of your plant layout. But they can be very cost-effective in the right application. We have both the technology and the creative designs to meet your needs. Our launders are well sealed, highly insulated and easy to clean.

ADVANTAGES:
- Metal quality – ensured through minimized turbulence and oxides.
- Highly insulated – to maintain temperature.
- Easy to clean.
- Reduces the need for transfer equipment.
- Reduces manpower and fork lift maintenance.
- Save ½ of 1% in metal melt loss caused by turbulent transfers into and from transfer ladles.
Dry Hearth Furnaces

We design Dry Hearth furnaces to melt aluminum ingot and large billet; no gassing or contamination by the lining means that metal purity remains high. Impurities and the oxide skin stay on the hearth as only molten aluminum enters the hold zone.

This versatile furnace meets the needs of a variety of metal casters, high and low pressure die casters, and permanent mold, sand, investment and lost foam foundries around the world.
Low Pressure Die Casting Systems

Schaefer’s Low Pressure Die Casting System (LPCS) is the latest in a long line of innovations. This system offers you the highest quality aluminum casting technology with the speed of conventional die casting.

The most technically advanced low pressure casting system provides turbulence-free fill through the mold bottom. This system uses the Schaefer Valve for non-turbulent transfer from a continuous Schaefer furnace (melted with utmost efficiency, degassed, filtered, at the exact temperature, at the exact time) supplying the LPCS.

ADVANTAGES:
- Highest Integrity Casting – no turbulence in the molten aluminum transfer and casting process means better castings.
- Cleaner Metal – comes from no turbulence in the entire molten metal transfer process (elimination of oxides or gas entrainment).
- Maximize Production Time – by continuous on-line furnace and casting equipment.
- Reliable and low maintenance equipment – continuous production means no more production disruptions to just refill it.
- Uninterrupted Production – via a large molten metal reservoir capacity in the delivery system.
Filtration Systems

High quality aluminum is often selected for critical cast parts used in aircraft, automotive, and computer industries, as these growing markets require better quality, greater strength, and improved machineability.

Filtration systems are powerful tools used to filter out inclusions, which reduces flaws, voids, and brittle planes of fracture. While reducing inclusions, the metal acquires increased fluidity, greater strength and ductility, improved machineability and better surface finish. All of those benefits lead to reduced tool wear, fewer rejects and less rework.

Schaefer is a pioneer in the design and installation of metal cleaning systems. We use a variety of filtration media, each chosen to meet a specific need. Our filtration solutions include filter plates, filter tubes, filter beds and sparging gases.

The basic Schaefer concept connects a highly efficient wet bath reverberatory melting furnace with a specially designed filter furnace. The reverberatory furnace provides low melt loss and high volume whereas the filter furnace delivers high quality, clean metal with very close and stable temperature control. Both furnace types can operate on the energy source preferred.

ADVANTAGES:
- Reduce Hydrogen – to eliminate impurities to produce clean metal.
- Reduce Porosity – to make stronger parts.
- Reduce Inclusions – to make better surfaces.
Degassing Systems

High quality aluminum is often selected for critical cast parts used in aircraft, automotive, and computer industries, as these growing markets require better quality, greater strength, and improved machineability.

Degassing systems are powerful tools used to filter out inclusions, which reduces flaws, voids, and brittle planes of fracture. While reducing inclusions, the metal acquires increased fluidity, greater strength and ductility, improved machineability and better surface finish. All of those benefits lead to reduced tool wear, fewer rejects and less rework.

Schaefer is a pioneer in the design and installation of degassing solutions. Our degassing solutions include porous plus technology, rotary sparging gas nozzles and degassing lances.

ADVANTAGES:
- Reduce Hydrogen – to eliminate impurities to produce clean metal.
- Reduce Porosity – to make stronger parts.
- Reduce Inclusions – to make better surfaces.
Crucible Pot-type Furnaces

Electric crucibles are used for melting or holding and are popular furnaces as they deliver exceptional efficiency. Completely covered, they use only 0.20 to 0.25 KW/hr per lb to melt cold metal and just 3 to 4 KW/hr to hold 1,000 lbs of molten aluminum at 1,220 degrees Fahrenheit. A built-in leak detector sounds an alarm if the silicon carbide crucible should ever leak.

Electric crucibles use less energy than channel-type induction furnaces, and they provide more accurate temperature control. Both manual and power-operated tilt-type versions are also available. Crucible furnaces are very compact and only require a small space to operate, and are a perfect companion in a complete Schaefer system of furnaces for a die casting, permanent mold or sand foundries.

ADVANTAGES:
- High Temperature Ceramic Fiber Lining – for walls, floor and top provide excellent insulation, low heat storage, and means it is cool to work near. It cannot be thermal shocked, which means it can rapidly be brought online or taken offline.
- Quiet operation
- Solid-state Controls – reliable, full-proportioning control system continuously meters in only the amount of power required at any given time.
- Easy Installation and Maintenance – easily connect the straight resistive electrical load in either single or three phase primary electric service.
- Long Service Life – depending on the ratio of melting to hold time, the silicon carbide crucible will outlast those in gas and oil-fired furnaces. The heavy duty electrical resistance heating elements usually deliver one to five years of service, and the lining will last even longer.
Transfer Ladles & Ladle Heaters

Our powered transfer ladles and ladle heaters can make light work of your foundry transport operations. We can provide custom ladles designed to fit specific needs with a range of: power options, barrel designs, single or multiple spout designs, and transport options.

ADVANTAGES:
- Rugged designs – for a long production life.
- Designed with simplicity – for easy operation
- Heavy-duty construction – long lasting in a production environment.
OPTIONS:
- Power options
- Barrel designs
- Single or multiple spout designs
- Transport options
Schaefer Shield

Schaefer Shield is a proprietary coating material that cleans the most difficult molten aluminum maintenance applications. Dross and oxide buildup are easily removed with a scoop. No more hammering (and damaging) refractory linings or tools. Steel or refractory can be coated with two different mixes.

Use Schaefer Shield for ease of cleaning molten aluminum from:
- Furnace Cleaning Tools
- Immersible Door Blades
- Ladle Cups
- Launders (periodic and continuous)
- Pouring Boxes
- Pump Components
- Thermocouple Protection Tubes
- Transfer Ladles
- Troughs
- Tundishes
ADVANTAGES:
- Reduces labor – cleaning linings is easy and fast.
- Reduces damage to refractory linings – remove buildup by simply scraping.