When you buy an induction furnace, look at the power supply rating in kW before the crucible size. Power decides how much metal you melt per hour. The crucible only decides how much liquid metal you hold at once. For cast iron, plan roughly 550–650 kW for every 1 t/h of melt.
Matching power and capacity
In grey and ductile iron, real-world consumption is 550–650 kWh per tonne. The theoretical figure is lower, but lid opening, slagging, sampling and holding push it up. Steel needs a little more.
A quick rule:
- A 600 kW furnace melts about 1 t/h of cast iron.
- A 1,500 kW furnace melts 2.3–2.7 t/h.
- A moulding line that needs 4 t/h of liquid metal needs around 2,500 kW.
Crucible size follows your pouring pattern. If you pour 30 kg per mould at 100 moulds per hour, a 1 t crucible empties often but works fine. A foundry casting single 800 kg parts needs at least 1.5–2 t.
Single or twin crucible
One power supply, one crucible: the cheapest layout. Melting stops while you pour. Enough for small and mid-size foundries.
One power supply, two crucibles with a switch: one melts while the other pours. During relining, production continues because one crucible is always spare.
Dual-output power supplies (Inductotherm VIP Power-Trak Dual-Trak, İndemak Duet Power and similar) split power between two crucibles at the same time: one melts, the other holds. This is the most efficient layout for foundries feeding an automatic moulding line.
IGBT or thyristor
Thyristor units are older technology but robust; many in Turkey have run for 20–30 years. Their drawbacks are harmonics and a low power factor, so they need compensation and filtering.
IGBT units have a high power factor, usually use a few percent less energy for the same job and offer finer control. Spare boards can cost more and fewer workshops repair them.
Before deciding, ask: does this brand have service in your country, and how many days does a board replacement take? Every day the foundry stands still costs more than the price gap between the two.
Transformer, cooling and power supply
An induction furnace is more than a power unit and a crucible. The budget also needs:
- Furnace transformer and MV switchgear. Above 1,000 kW a dedicated transformer is usually required, and a grid capacity upgrade can take months.
- Closed-circuit cooling for the coil and power unit: tower, pumps, heat exchanger.
- Hydraulic tilting and lid system.
- Charging: vibratory charge car or magnet crane.
When comparing offers, tick which items each one includes. A cheap offer usually leaves out the transformer or cooling.
Lining and coil
Cast iron foundries mostly use silica (acid) lining. Lining life depends on alloy, temperature, charge material and sintering quality; a well-sintered lining can last twice as long as a poor one. Check whether the furnace has an automatic sintering program.
The coil is the most expensive and most critical part. Check it regularly for water leaks, insulation wear and cracked coil supports.
Buying a used induction furnace
We bring used furnaces from Europe and Turkey. Chosen well, a used furnace runs for years at about half the price of new. Checklist:
- Year and type of the power unit (IGBT / thyristor), nameplate photo.
- Video under load: does it reach full power, any alarms?
- Coil condition: leaks, insulation, date of last replacement.
- Is the cooling system included, and in what condition are tower and pumps?
- Are the transformer and MV cells included?
- Wiring diagrams, PLC program and manuals.
- Who dismantles and ships, and will cables and busbars be labelled?
- Are spare parts and service available locally?
Some furnaces we currently offer:
- ICS 600 kW IGBT, 1,000 kg, 2019, transformer and cooling included: ZEN-1997
- Inductotherm VIP Power-Trak 3 t, 1,500 + 250 kW: ZEN-1907
- Inductotherm 1.5 t single crucible with closed-circuit cooling: ZEN-1952
- İndemak Duet Power 2 × 1 t: ZEN-1969
See all melting equipment on the Used Machinery page under "Induction furnaces & melting".
FAQ
How many tonnes per hour does a 1 t induction furnace melt?
Power decides, not crucible size. A 1 t crucible with a 600 kW supply melts about 1 t/h of cast iron.
How many kWh per tonne does an induction furnace use?
About 550–650 kWh/t for cast iron in practice; a little more for steel.
Does it make sense to switch from cupola to induction?
For most foundries yes, because of emission permits, coke prices and analysis control. See our cupola furnace guide.
Who installs a used furnace in Turkey or the region?
ZENES handles dismantling, transport, installation and commissioning. Send the listing code on WhatsApp for an offer.
