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The commitment to delivering excellence through advanced technologies continues to shape Texmo Blank Group’s operational strategy. This commitment was again demonstrated in May with the commissioning of a remelting unit at the Riedlingen site of Texmo Blank Germany. Developed in collaboration with an external partner, the new system significantly increases process efficiency by enabling a key foundry step to be performed in-house.
‘A remelting unit processes metal by remelting circulating material that is separated from the final precision cast parts after casting, and prepares it in ingot form for future use,’ explains Andreas Schmid, Plant Engineering & Automation Manager at Texmo Blank. ‘Previously, this process was carried out externally. By bringing it in-house, we are now able to reduce both time and cost.’
In addition to these efficiencies, the shift reduces reliance on external partners, improving planning reliability. Overall, lead times are shortened, and capital tied up in the process is reduced.
‘Quality is another important dimension of the system’s benefits,’ adds Thomas Rindert, Vice President of Quality. ‘An added environmental benefit is the reduction of lorry journeys, which cuts CO₂ emissions by approximately 40 tonnes annually.’
Ceremonial Commissioning with the Project Team
At the official ceremony held in mid-May, Andreas Schmid outlined the strategic advantages of the unit before Werner Blank, former Managing Director of the Riedlingen foundry, formally inaugurated the system. The event was attended by the entire project team and all employees involved in the planning and installation phases.
Managing Director Arjunan Ramachandran thanked the team in his address:
‘Commissioning this system marks a strategic milestone and the beginning of a profound transformation. It will play a central role in shaping the future of the Riedlingen site. Today represents the start of a process that strengthens our foundation and positions us to thrive in an increasingly competitive environment.’
A Highly Efficient Melting Process for Maximum Quality
The new remelting unit features an advanced exchange system designed for optimal efficiency and cycle time. It includes three melt boxes, each with a capacity of 350 kg, enabling rapid switching during loading and unloading. Three mould tables operate in parallel, each accommodating up to 13 moulds per cycle, yielding up to 26 ingots.
The melting process begins once the chamber is sealed and a vacuum is applied. An initial 160 kg load is melted, followed by 10–15 kg increments added via a dedicated charging chamber, repeated up to 20 times per cycle to reach the 350 kg target. Simultaneously, the tundish (casting channel) is preheated to 900 °C. Once the melting temperature of up to 1,400 °C is achieved, casting begins. The molten metal is precisely poured into the moulds using a joystick-controlled system.
After casting, the chamber is ventilated and opened, allowing the removal of the empty melt box and mould table. The system is then reloaded to start the next cycle. Outside the chamber, components are cooled and prepared for the next casting. This highly efficient and precise process sets new benchmarks in in-house alloy production.
A Strategic Investment Supporting Future Growth
Following the commissioning, guests participated in a lively exchange during a brief get-together. Reflecting on the event, Arjunan Ramachandran once again emphasised the broader significance of the new unit:
‘This is a major step forward - not only technically, but strategically for the Riedlingen site. It underlines our ambition to lead through innovation and to invest purposefully in our future.’
