Horizontal Continuous Casting Machine for Copper and Aluminum: What It Makes and How to Choose
A horizontal continuous casting machine is a complete production line — not a single furnace — that turns molten metal into rod, bar, tube, or plate in one uninterrupted process. Metal is melted and held in the casting furnace, drawn through a water-cooled graphite mold by the withdrawal machine, solidified as it leaves the mold, then cut to length or coiled. Luoyang Wanfeng Industrial Furnace Co., Ltd. (Wanfeng Furnace) has built these lines since 1990 for copper and aluminum processors worldwide.
What a complete line includes
- Casting furnace — a medium-frequency induction casting furnace for copper; a resistance holding/casting furnace for aluminum (induction optional)
- Mold assembly — water-cooled graphite mold mounted on the furnace
- Withdrawal machine — pulls the cast section at a controlled speed; available for strand sizes from 4 to 400 mm, in single-strand, split multi-strand, and integrated multi-strand layouts
- Finishing equipment — cut-to-length saw or automatic coiler, matched to the product
Furnace configuration depends on metal and output. For copper, output above about 200 kg/h calls for a separate melting furnace and holding furnace; below that, a combined melting-and-holding furnace works. For aluminum, a separate melting furnace is always required — the resistance furnace on the line is a holding/casting furnace only, and the melting furnace is sized to match the casting output.
Start-stop on demand — the key difference
Wanfeng’s medium-frequency induction casting furnace (copper) and resistance holding/casting furnace (aluminum) both support start-stop on demand: run when there are orders, stop when there are none — without the holding-furnace energy waste of line-frequency furnace lines.
- Planned stops follow the operating procedure — drain the remaining melt before shutdown, because leaving a full furnace of liquid shortens crucible life
- Grade change without furnace washing — switching copper alloy grades means replacing the crucible directly; a line-frequency furnace must be washed instead
- Power outage protection is cheap — the furnace can stop, but cooling water must keep running; a small diesel generator for the cooling tower is enough. A line-frequency furnace needs a large generator to keep both the furnace (at holding power) and the cooling tower alive
Key specifications
| Parameter | Value |
|---|---|
| Furnace body capacity | 100 kg–6 t, rated by copper density; convert by density for other metals |
| Medium-frequency power | 80–2000 kW, sized by furnace capacity |
| Melting rate | 1 t/h |
| Temperature control accuracy | ±1 °C |
| Withdrawal speed | 50–800 mm/min |
| Resistance holding furnace power (aluminum) | 18–200 kW |
| Plant requirements | Ceiling height ≥6 m; footprint >3 m × 6 m |
| Cooling water circulation | ≥30 t/h |
Strand count and mold configuration are customized by application — one resistance casting furnace can cast 1 to 50 strands of aluminum rod depending on section size. Contact Wanfeng Furnace for your target product.
What it can produce
- Copper — rod, bar, tube, plate
- Aluminum — rod, bar, plate
- Also configurable for — steel, iron, high-temperature alloys, zinc, lead
- Sections — round and square billets up to 120 × 120 mm from one mold opening; hexagonal bar and special profiles on request
Finishing follows the material: bars, tubes, and plates are cut to length (copper alloys always). Rod and wire can be coiled — pure aluminum rod up to 12 mm, pure copper rod up to 30 mm; harder alloys are assessed case by case.
Who it suits
The line fits non-ferrous plants that run intermittent, multi-batch, or small-batch production — and equally plants that need long stable runs. If your order book fluctuates, start-stop on demand means the furnace follows your plan instead of forcing you to feed a furnace that never sleeps.
Wanfeng Furnace has delivered casting equipment to Eastern Europe, Southeast Asia, and South Asia, and holds CE certification with independent import/export rights.
FAQ
What can a horizontal continuous casting machine produce?
Copper rod, bar, tube, and plate, plus aluminum rod, bar, and plate. It can also be configured for steel, iron, high-temperature alloys, zinc, and lead. Round and square billets up to 120 × 120 mm, hexagonal bar, and special profiles are possible.
Can the machine run intermittent or small-batch production?
Yes. Both the copper and aluminum casting furnaces support start-stop on demand, so the line runs when there are orders and stops between them — without holding-furnace energy waste.
What happens during a power outage?
The furnace can stop, but cooling water must keep running. A small diesel generator supplying the cooling tower is enough to protect the equipment.
Do I need to wash the furnace when changing alloy grades?
No. Switching copper alloy grades means replacing the crucible directly. For planned stops, drain the remaining melt before shutdown to protect crucible life.
Do I need cut-to-length or a coiler?
Bars, tubes, and plates use cut-to-length; copper alloys are always cut to length. Rod and wire can be coiled: pure aluminum rod up to 12 mm and pure copper rod up to 30 mm. Harder alloys are assessed case by case.
How is the furnace configured for copper vs. aluminum?
For copper above about 200 kg/h output, a separate melting furnace and holding furnace are recommended; below that, a combined melting-and-holding furnace works. For aluminum, a separate melting furnace is always required — the on-line resistance furnace is a holding/casting furnace only.
What does a complete line include?
Casting furnace (medium-frequency induction for copper; resistance holding/casting for aluminum), mold assembly, withdrawal machine, and cut-to-length or automatic coiling equipment. Withdrawal machines cover strand sizes from 4 to 400 mm in single- or multi-strand layouts.
How much does it cost?
Price is customized by configuration. Send Wanfeng Furnace your target product and output for a sized quote: phone +86 17796741029, email zhang@wanf-furnace.com.
Product page with full configuration details: Horizontal Continuous Casting Machine.
Wanfeng Furnace — continuous casting and induction melting equipment manufacturer based in Luoyang, China. Manufacturing history since 1990; formally incorporated in 2009.
