The West Midlands, Birmingham and Coventry Branch of the ICME held its first technical lecture of the 2025/26 season on Monday 1st September 2025 at Churchill’s in Wednesbury, with an attendance of 28 members at the venue and a number of members joining on line.
We were pleased to welcome Sam Wainwright Prof MICME from the Inductotherm Group, who presented an in‑depth lecture titled “Induction Furnaces… Optimising Equipment to Minimise Energy Consumption.” Sam’s extensive knowledge and hands‑on experience in melting metals using induction furnace technology was evident throughout the presentation.
As the casting industry remains a major consumer of electricity—and with the sector moving steadily toward Net Zero—understanding and reducing energy losses has never been more important. Sam highlighted the significance of identifying inefficiencies such as reactive power (VAR) and demonstrated how modern equipment and improved melting practices can significantly mitigate these losses.
During the lecture, Sam explained that, in collaboration with the foundry, it is possible to:
- Utilise the latest inverter technology to improve efficiency and minimise losses.
- Achieve high power factors across all operating levels.
- Maximise efficiency through high power‑to‑weight ratios, particularly when using batch melting.
- Select and operate the correct furnace accessories, including closed fume hoods and optimised extraction rates.
- Develop efficient plant layouts and power transmission systems to reduce energy losses.
- Analyse and collect operational data to refine processes and reduce energy consumption.
- Install energy‑recovery systems, such as heat‑recovery solutions, to further enhance sustainability.
The evening concluded with a buffet kindly sponsored by the Inductotherm Group, whose support contributed to a successful and engaging event.
Mark Holliday Prof MICME
