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Enhancing Thermal Containment in Your Furnace
What is Thermal Containment?
Industrial furnaces and heat treating equipment are designed to manufacture and refine materials to the highest standard of consistency and quality. They are not designed to be the most energy-efficient piece of equipment. Overlooking optimal thermal containment leads to a higher energy costs and reduced per unit proifitability.
How to retrofit your Furnace with Thermal Containment Solutions
Our solutions do not require investment in new multi million dollar equipement. Instead we work around the edges to "un-cut" corners that were overlooked in the furnace design process.
How we can help
We provide custom and off-the-shelf solutions using a combination of ceramic and vitreous textiles. Our patent pending magnetic insulation curtains allow you to quickly patch hotspots up to 1400C within minutes. Alternatively, with your desired design specifications, we can customize sown shapes in combined chemistries to control heat loss from conductive, convective, and radiant vectors.
Other Benefits to Retrofitting Your Furnace
6 sigma
The 6 sigma blackbelts know that minimizing deviations in all processes is the key to process improvement:
- Maintaining Uniform temperature in eat treatment, sintering, or casting furnaces directly affects part quality
- Reducing temperature overshoots that cause material distortions or non-uniform phase changes
- Fewer deviations = fewer rejects, which aligns with Six Sigma's goal of <3.4 defects per million opportunities
Employee Safety & Comfort
In high-heat industries (foundries, metal works, furnace operations), heat-related illness is the leading hazard!
- Employers are required under the General Duty Clause (Section 5(a)(1)) to protect workers from recognized hazards, including excessive heat.
- In 2024 the maximum penalty for serious violations was $16,131 per instance.
- Willful or repeat violations can cost up to $161,323
Lower Maintenance and Downtime
Improved insulation and thermal containment dramatically reduce unscheduled furnace shutdowns and component fatigue caused by heat leakage. Over time, runaway heat can damage sensors degrade factory linings, and warp nearby hardware.
- The U.S. Department of energy DOE has stated in its Advanced Manufacturing Office documents that: "Improved insulation materials and heat containment systems can significantly extend equipment life and reduce operational disruptions due to overheating and material degradation.
- NIST (The National Institute of Standards and Technology) also emphasizes the importance of thermal control in process reliability, especially in high-temperature environments: "even small inefficiencies in Thermal Shielding can lead to cascading failures in equipemnt designed for tight temperature tolerances".
ESG & C02 Reporting Requirements
Reducing carbon footprint will help to comply with various reporting standards. Thermal containment measures help to:
- Lower fuel consumption
- Reduce GHG emissions per unit produced, improving your intensity metrics (CO 2 / ton output)
- Supporting Scope 1 emissions reporting