With a power of 1,200 kW and a capacity of 1,700 kg of cast iron, the OTTO JUNKER furnace replaces the cupola used previously and lowers CO₂ emissions during the melting process by approx. 330 tons per year. Apart from a precise process control, the system allows for a stable power control which can be ideally integrated into existing energy structures.
A central element is the glycol-free air/water recooler with integrated heat recovery. It uses the heat produced during the cooling process for reverting energy into downstream processes thus increasing the overall efficiency of the business. This solution reduces energy consumption, avoids additional operating resources and lowers maintenance requirements. The OCP+ temperature monitoring system has been installed for permanent process monitoring. It continuously detects coil and crucible temperatures, providing a high operational safety. Due to the modular arrangement of the MONOMELT system, the equipment could be adapted to the spatial and energetic conditions on site.
The conversion to induction was a logical step for us on our way towards CO₂ neutrality. The plant runs reliably, and we see significant efficiency gains in everyday operation Klaus Schultz, General Manager of Eisengießerei Schultz, explains.
The project shows how conventional foundry processes can be made sustainable with state-of-the-art technology – and still be economical”, Andreas von Wachtendonk, Regional Sales Manager – Foundry Plants, OTTO JUNKER, elaborates further.
Experience made during the first year of production
Since the project was announced in 2024, initial results from regular operation are already available. The plant has been running at full capacity since February 2025. Compared to the cupola used previously, the energy consumption could be reduced by about 50 % while at the same time increasing process stability and achieving a more homogeneous melting quality.
In addition to that, the workplace comfort has been significantly improved due to lower dust and noise emissions – an aspect not to be underestimated for medium-sized companies consistently trying to improve workplace conditions.
The conversion required a close cooperation between OTTO JUNKER and the customer: From the planning and design stage and the integration into the existing infrastructure to the commissioning and training of the operating personnel.
Induction as the technological basis for transformation
Throughout the foundry industry, induction furnaces have established themselves as an efficient and sustainable technology. They enable precise temperature control, flexible batch sizes and can be directly operated by means of renewable power – a decisive advantage in the course of the industrial energy transition. Particularly for medium-sized companies, the change from fossil combustion to electrical melting processes offers a practical solution in order to achieve emission and efficiency targets.
For this purpose, OTTO JUNKER offer complete system solutions covering all relevant components – from coreless furnaces, cooling systems, control technology and monitoring systems to energy integration. We support our customers from feasibility studies all the way to the commissioning and offer comprehensive services for modernization, retrofitting and energy optimization.
About Eisengießerei Th. Schultz GmbH & Co. KG
Eisengießerei Th. Schultz GmbH & Co. KG
The family-owned company based in Warendorf/Germany looks back at more than 65 years of experience in producing high-quality cast iron products.
Among its customers are companies from the automotive industry, mechanical engineering and tool making, conveyor technology, medial technology and the music industry. As a member of the “Climate friendly medium-sized companies” network, Eisengießerei Th. Schultz pursue a clear strategy to reduce their CO₂ footprint placing an emphasis on efficiency, innovation and regional partnerships.
