Case Study · Iron & Steel
Auto-Pour Ladle High Emissivity Coating: Service Life Doubled at Redline Industries
| Industry | Iron & Steel |
|---|---|
| Asset | Auto-pour ladles (stainless, aluminium casting) |
| Customer or location | Redline Industries, USA |
| Products used | Emisshield STG-1 |
| Headline metric | 200% life increase |
| Secondary metric | 20,000 to 40,000 pours |
Redline Industries coated the stainless-steel auto-pour ladles in its aluminium casting operation with Emisshield STG-1. Coated ladles reached 40,000 pours before repair against 20,000 uncoated, with far less slag adhesion, chemical attack, and thermal-shock cracking.
01
What was the challenge?
Abrasive slag and intense heat wore out the ladles after about 20,000 pours. Management wanted longer ladle life and lower maintenance cost without redesigning the process.
02
What was applied?
Ladles were grit-blasted and cleaned, then coated by HVLP spray with STG-1 across the entire refractory lining, including the dam and pour spout. No sintering was needed. Ladles returned to service at 704°C and were compared with uncoated control ladles.
03
What were the results?
| Metric | Uncoated | Coated |
|---|---|---|
| Service life | ~20,000 pours | 40,000 pours |
| Run count | Baseline | +200% |
| Slag adhesion and chemical corrosion | Constant | Dramatically reduced |
| Thermal-shock cracking and repair frequency | Recurring | Reduced |
Coated ladles remained in service twice as long, with substantial maintenance savings; ease of application and immediate return to service made the coating cost-effective.
04
Why did it work?
STG-1's sealed high emissivity ceramic face absorbs preheat energy efficiently and presents a surface that slag does not wet, while its thermal-shock tolerance protects the lining through pour cycles. See Production Increase, component life.
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