For decades, Tempco has set itself apart in the industrial heating industry with an in-house foundry, a rare capability that has long allowed for the production of high-quality cast components tailored to customer needs. Today, that tradition continues with investments into new state-of-the-art foundry equipment designed not to reinvent the process but refine it.
More Furnaces, More Flexibility
Tempco has recently expanded the capabilities of its foundry by adding three new furnaces to the factory, enabling faster and more efficient capabilities when it comes to casting of products for clients. Two traditional electric Shafer furnaces, a large induction furnace from Inductotherm, and two smaller Inductotherm furnaces from a previous expansion are now part of the Tempco foundry.
The induction furnaces possess the ability to melt virtually any metal type. Tempco can melt 150 or 225 pounds of aluminum in each of the smaller induction furnaces. For any higher-density metals, such as brass, bronze, or cast iron, a higher level of weight can be utilized due to volume-based measurements. Because induction furnaces can melt virtually any type of metal using less than half the electricity of older models, more castings can be produced with the same energy cost.
Perhaps the biggest change that can be seen with these new foundries is the flexibility they come with. In the past, casting different parts often meant waiting for the furnace to cool down or heat up to a new temperature. A large batch would require long waits to add metal, which cools the furnace, then waiting for said temperature to stabilize.
“Our angle is that it does bring us new capabilities,” said Chris, Maintenance Manager at Tempco, “It makes it so that we can do what we need to do more efficiently, more nimble, and switch between metals more easily.”
“We have a wider range of production capabilities than before,” Chris added, “We can switch between stuff. We can use multiple different temperatures of aluminum if we need to or add metal to one furnace and let that melt down while using another — it’s ready by the time we need it.” This means less idle time, more production, and the ability to handle complex, varied orders without sacrificing throughput.
Automation Brings Consistency and Safety
Efficiency isn’t just about speed; it’s also about repeatability and safety. Tempco’s new permanent mold machine replaces older, worn-out units with new, state-of-the-art automation that makes each casting more consistent while also making the foundry safer for its employees.
“The important part on this is also the safety part of it,” said Ricardo, the Cast-in Heater Production Manager at Tempco. “The operator can run these machines safely — it’s not only new technology, but safety is a big thing.”
The new machines feature push-button control for tilting, operation, and part ejection, along with the ability to store and recall programs for specific part numbers. That means precise timing, consistent results, and less manual intervention. Making each Cast-In heater created a much more coherent unit with the other. “If you wanted to just push a button, the machine will take care of the rest,” Ricardo added, “It tilts, moves, ejects the part, and can even store programs so you can run the same part number later with a single press.”
Safety is also built into the design. Operators must hold a button continuously during operations, utilizing a “dead-man switch” feature, and controls are positioned away from moving components, reducing the risk of accidental contact. Seven different castings have already been produced on the new equipment, and more are in development. Three machines are currently fully operational, while a fourth, featuring a specialized casting catcher arm, is undergoing setup and testing.
Handling Bigger Molds with Ease
Foundry operations are as much about the quality of the molds as they are about the metal. With that in mind, Tempco’s tool and die department continues to create permanent metal molds and our in-house pattern shop creates single-use sand molds tailored to customer needs.
The foundry now features a powerful new mold manipulator, capable of handling sand molds up to five tons and 80 inches in width. This “big claw,” as it’s affectionately known on the floor, automates heavy lifting, reduces manual strain on workers, and enables safe, controlled movements and rotations of larger models. Another example of how Tempco’s modernization improves both productivity and workplace safety.
Building on Experience with Modern Tools
What makes these investments significant is not that Tempco can now cast different metals or create entirely new products; it’s that every part of the foundry process has become more nimble, efficient, and precise. By updating the core equipment, Tempco ensures faster turnaround times, safer operations, and a higher overall output, all while maintaining the flexibility and expertise customers have trusted for decades.
With these new tools in place, the foundry is ready to meet growing demand and support a wide range of custom applications. Whether you need a specialized alloy casting, a custom-engineered heater component, or guidance on designing the right thermal solution for your process, Tempco’s team is here to help.
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