A mid-sized steel foundry in Ahmedabad, Gujarat, operating a 3-ton induction furnace, faced repeated refractory lining failures every 18–20 heats. Despite using high-quality materials, manual ramming led to uneven compaction, premature cracking, and increased downtime.
After partnering with LeisterTech and installing the Model X Lining Vibrator, the plant extended its lining life, reduced waste, and saved over ₹6 lakhs annually—without the need for major automation investments.
The Problem: Inconsistent Ramming, Early Failures
The foundry team relied on manual ramming techniques to install high-alumina refractory linings. However, they experienced:
Uneven compaction, especially in the lower crucible
Cracks forming after just 12–14 heats
Frequent downtime of 3–4 days per month
High operator fatigue and labor dependency
Material wastage of up to 12% per lining batch
These issues led to rising maintenance costs and production inefficiencies.
The Solution: LeisterTech Model X Lining Vibrator
LeisterTech’s engineering team conducted a free technical audit and recommended the Model X Lining Vibrator, customized to the furnace’s dimensions and refractory mix.
Key Features:
Adjustable RPM range (2200–2800) for various material densities
Wide vibration head for complete crucible coverage
Reinforced portable base for mobility and durability
Operator training included to ensure best practices
View detailed specifications here
Results Within 60 Days
Performance Metric Before Model X After Model X
Lining Lifespan 18–20 heats 29–32 heats
Monthly Downtime 3–4 days Less than 1 day
Refractory Material Waste ~12% Under 5%
Operator Fatigue High Low
Annual Maintenance Cost ₹8.5 lakhs ₹2.4 lakhs
“This one tool paid for itself in just two months. We didn’t realize how much we were losing until we stopped losing it.”
— Foundry Manager, Ahmedabad
Key Takeaways
Mechanical vibrators ensure consistent compaction and minimize voids and cracks.
Reduces dependency on manual skill, leading to more reliable results.
A cost-effective upgrade that improves furnace performance without large investments.
Custom vibration systems available for all furnace sizes and refractory types.
Browse all lining vibrator models
Continued Support from LeisterTech
Beyond installation, LeisterTech offers complete support to ensure long-term efficiency:
Free on-site demos and vibration tests
Annual servicing and upgrades
Custom-engineered solutions
Training and audits for in-house teams
📩 Book a lining audit today
📞 Call: +91 93289 16310 / +91 99091 79617
✉️ Email: info@leistertech.com
🌐 Visit: leistertech.com
Ready to Reduce Downtime and Improve Lining Performance?
If your foundry is struggling with frequent lining failures, LeisterTech’s Model X Lining Vibrator offers a smart, simple, and proven solution. Increase lining life, reduce waste, and boost ROI—just like this Ahmedabad foundry did.
🔗 Get started with LeisterTech today