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MELTING & HEAT TREAT.

Four Furnaces. Built for Continuity.

60,000 lbs. of daily melt capacity across four independent furnaces — with in-house heat treat for brasses, bronzes, and stainless.

Excal’s four independent melting furnaces provide the melt capacity and continuity to support both high-volume production programs and urgent specialty pours. With 60,000 lbs. of combined daily capacity and up to 4,000 lbs. in a single pour, we have the scale to keep your program on schedule — and the redundancy to ensure one furnace down never means your production stops.

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Why Four Independent Furnaces Matter

Capacity and Continuity — Not One or the Other

A single furnace is a production bottleneck waiting to happen. Four independent furnaces means Excal can melt multiple alloys simultaneously and maintain output even during maintenance cycles.

60,000 lbs/Shift Combined Capacity

Combined melt capacity of 60,000 lbs. per shift — currently operating one shift, with additional capacity available. supports both high-volume steady programs and large one-time pours — without scheduling conflicts.

Up to 4,000 lbs. Per Single Pour

Single-pour capacity of up to 4,000 lbs. allows Excal to produce large individual castings — a range that many smaller foundries cannot match.

In-House Heat Treat

Our in-house heat treat furnace handles brasses, bronzes, and stainless alloys — keeping thermal processing under our roof and off your critical path.

Our Process — Melting & Heat Treat

From Raw Alloy to Certified Pour

1

Alloy Preparation


Certified raw materials are sourced and prepared for the furnace. Alloy composition is regularly checked with our in-house spectrometer through continuous spot checking throughout production.

2

Melting & Chemistry Verification

Metal is melted. Pour records are kept within our ERP system for easy reference. Alloy composition is spot checked using our in-house spectrometer throughout production.

3

Pouring

Approved metal is poured into prepared molds at controlled temperature. Pour records are maintained for full traceability.

4

Heat Treatment (where specified)

Castings requiring heat treatment are processed in our in-house furnace to customer or applicable standard specifications.

FAQ — Melting & Heat Treat

Your Questions, Our Answers

We use an in-house optical emission spectrometer to verify brass, bronze, and stainless steel chemistry through continuous spot checking throughout production. Results are recorded and available for traceability. We also perform testing using outside labs, if desired, for independent approval including chemical and physical testing.

Our primary capability is brass and bronze, including a broad range of C-alloy grades. We also melt select stainless steel alloys. See our Alloys page for the full list.

We perform heat treatment to customer-specified requirements for brasses, bronzes, and stainless alloys. Contact our team with your specification and we’ll confirm our capability.

Yes. We supply testing results when required and asked for. Spectrometer results are not provided with every shipment as standard. Material certifications are backed by our ISO 9001:2015 quality management system. documentation — backed by our ISO 9001:2015 quality management system.

Ready to Discuss Your Alloy and Pour Requirements?

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