UPCAST® Technology
UPCAST®
Process
The UPCAST® system produces high-quality rod and tube for various applications. It is a straightforward process with user-friendly operation, managed through an advanced control system. UPCAST® lines are customized to meet each customer’s diverse needs, with core components including charging equipment, a furnace system, a casting machine, and coilers. The cathode and/or recycled copper charging system and rod/tube coilers are individually designed to match each line’s requirements.

Raw material
To produce high-quality oxygen-free (Cu-OF) rod or DHP tube, the preferred raw material is copper cathodes. Cathodes are the primary material used in our process; however, recycled copper can also be utilized. Recycled copper must be as clean as possible and requires a longer dwell time in the melting furnace before the casting process begins. Therefore, using a dedicated melting furnace for copper scrap is recommended.
Furnaces
Depending on capacity requirements, there are several furnace types to choose from. All furnaces are electrically heated with channel inductors, available in single- or double-loop types. A stepless power supply and control system is standard, ensuring smooth power adjustments that optimize energy efficiency, extend inductor service life, and eliminate harmonic resonances from the inductor circuit.
- Single-furnace configuration: Recommended for casting capacities up to 12,000 TPA, this compact, open-top unit integrates both melting and casting functions in a single furnace.
- Double-furnace configuration: Suitable for casting capacities up to 40,000 TPA, this system has separate melting and casting furnaces.
- Triple-furnace configuration: Designed for operations using both cathodes and recycled copper as raw material, this setup includes two melting furnaces (one for cathodes and one for recycled copper) and a dedicated casting furnace for optimal performance.
Casting machine
UPCAST® casting machines are multi-strand systems, with each strand equipped with an individual cooler. Higher production output requires more strands, ensuring scalability based on capacity needs. The coolers are fixed to the casting machine frame, which is positioned above either a combined melting/casting furnace in single-furnace configurations or a dedicated casting furnace in double- and triple-furnace setups.
The servomotor-driven system pulls the cast products upward through coolers. From there, the rods/tubes are guided to coilers. Typically, double coilers are used for rods and individual coilers for tubes, which are a more robust product.
The UPCAST® system allows simultaneous casting of different product sizes. Switching between cast products is as simple as replacing the coolers and selecting the corresponding casting program in the computer-controlled servo-motor drive system. Multiple drive systems can be integrated into the same frame, enabling the casting of different rod or tube sizes at the same time. Adding or removing coolers does not interrupt ongoing casting, ensuring high process availability. Daily production output adjustments are easily managed by varying the number of active strands.