HYBRID SUCCESS IN ACTION – REAL FOUNDRY RESULTS FROM KALTHARZ 8500
The introduction of the Kaltharz 8500 Hybrid Binder System has marked a turning point for foundries striving to combine sustainability with performance.
Across the world, real-world applications in nodular cast iron, ductile iron, and steel casting have proven that hybrid binder technology delivers tangible results
— not just in emissions reduction, but in casting quality, cost control, and process reliability. The system’s hybrid chemistry, which merges the advantages of
furan and phenolic binders, enables foundries to achieve cleaner operations and higher-quality outcomes with improved process efficiency.
SUCCESS 1: NODULAR CAST IRON – CLEANER, MORE EFFICIENT PRODUCTION.
In nodular cast iron production, the use of traditional furan systems often leads to sulfur accumulation in reclaimed sand, resulting in casting defects
and high coating costs. After switching to the Kaltharz 8500 hybrid system, foundries recorded significant improvements in both environmental and
operational performance. The sulfur content in reclaimed sand was drastically reduced, producing visibly cleaner cores and smoother casting surfaces.
Graphite degeneration beneath the casting surface decreased from around 500 micrometres to just 100 micrometres, demonstrating a major enhancement
in metallurgical quality. Moreover, the transition allowed foundries to replace costly zircon coatings with more economical aluminum silicate coatings — achieving
the same high-quality finish while reducing material expenses. These combined results strengthened both the ecological footprint and economic efficiency of
production, delivering clear advantages for foundry operations.
SUCCESS 2: DUCTILE IRON – STRENGTH AND SUSTAINABILITY
For ductile iron applications, where strength and surface integrity are essential, the KaLTHARZ 8500 hybrid binder system has proven its value.
Heavy-duty components such as marine gearboxes and press parts benefited from the technology’s stability and versatility. The foundries achieved
the same high level of mechanical performance while reducing the resin dosage from 1.1% to 0.9%, cutting material consumption without compromising
quality. Castings weighing up to 19 tons displayed improved mechanical strength and smoother surfaces, while reclaimed sand exhibited lower sulfur
and nitrogen levels. This cleaner sand enhanced mold consistency and reusability, contributing to a more efficient and sustainable production cycle.
The hybrid binder system’s stable curing behavior, reduced emissions, and lower operating costs have established it as a reliable solution for
demanding ductile iron applications.
SUCCESS 3: STEEL CASTING – CLEANER CHEMISTRY, SAME STRENGTH
The benefits of hybrid binder technology extend into steel casting as well. Foundries transitioning from strong acid activators containing
2% sulfuric acid and 14% sulfur to milder systems with less than 1% sulfuric acid and 11% sulfur reported a 25% reduction
in sulfur emissions. These foundries experienced improved air quality in the working environment and reduced chemical exposure,
contributing to safer and more sustainable operations. At the same time, the mechanical stability of the castings remained exceptional,
even under high-temperature conditions. Both chromite and silica sands retained their strength and stability across multiple reclamation
cycles, confirming the system’s ability to support repeated use without degradation. By reducing acid intensity and sulfur levels,
the KALTHARZ 8500 hybrid binder allowed steel foundries to maintain top-tier casting quality while improving worker safety and
environmental compliance.
THE BIGGER PICTURE.
Across all three case studies, a consistent message is clear: hybridisation works. The KALTHARZ 8500 Hybrid Binder System reduces
harmful emissions, extends sand life, lowers production costs, and maintains or enhances mechanical performance. It demonstrates
how forward-thinking chemical engineering can modernize traditional foundry processes, transforming ecological responsibility
into a competitive advantage.
DZANETECH’S COMMITMENT.
As a trusted supplier of KALTHAZ 8500, DZanetech continues to champion solutions that make foundries
more efficient, sustainable, and future-ready. Through innovation and partnership, the company helps foundries across South Africa
and beyond embrace cleaner, smarter, and more productive operations. To learn more about implementing Kaltharz 8500 in your
foundry or to schedule a technical consultation, contact DZanetech’s foundry solutions team today.
