The Power of Microspraying in Casting

Microspraying is revolutionizing the HPDC industry by offering unparalleled efficiency, sustainability, and cost-effectiveness advantages. This innovative technology, championed by solutions like Chem-Trend’s HERA™ (High-Efficiency Release Agent), provides a game-changing approach to release agents that benefits both production processes and the planet.

Double Digit Efficiency Gains

Microspraying involves the precise application of concentrated release agents, such as HERA™, directly to critical areas of the mould surface. Unlike traditional methods that rely on heavily diluted water-based emulsions, microspraying minimizes overspray, reduces thermal shocks, and ensures optimal coverage where needed.

One of the most significant benefits of microspraying is enhanced efficiency. As the demoulding layer in the spraying is applied and the die is not cooled by water, microspraying significantly reduces spray times. This shortens cycle times by up to 30% and allows foundries to achieve higher productivity. Conventional methods involve spraying water to cool the tool and applying the release agent. This leads to thermoshocks and early heat cracking in dies. Good thermal management extends the die’s life and reduces maintenance needs. This allows for higher margins as heat cracks do not form that has to be manually ground off.

Achieve massive Energy Savings

The waterless application also ensures an even release film, reducing the risk of micro-porosity and other defects in cast parts. This results in higher-quality components that perform well in subsequent processes like welding and coating.

Microspraying is also a significant step forward for sustainability, leaving a positive handprint by cutting fresh water consumption by up to 99%. With virtually no wastewater and significantly lower scrap rates, typically reduced by 10-15%, this method directly supports environmental goals and operational sustainability. Beyond environmental benefits, microspraying offers financial advantages that are impossible to ignore. By minimizing the need for water, foundries not only cut costs but also alleviate the environmental burden of wastewater treatment. Reduced water usage means less energy is required to reheat moulds, leading to energy savings of up to 20-30%. Improved consistency and part quality reduce costs associated with rejected components, while shortened cycle times enable foundries to produce more parts in less time, directly impacting profitability.

Microspraying is more than a technical advancement; it is a pathway to a sustainable and profitable future for foundries. With solutions like HERA™ leading the charge, the foundries with microspray implemented aim to enhance efficiency and environmental responsibility, ensuring their long-term viability and success.

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