UPCAST® Technology

The original upward casting method

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.

UPCAST®
Technology & Development

UPCAST® Rod

Maximum versatility,
minimum costs.

The majority of UPCAST® lines produce rod, including both Cu-OF and alloys. The most commonly cast rod diameter is 8mm, which is the industry standard for wire and cable production. Larger diameters are cast for manufacturing a variety of products such as bus bars, profiles, and trolley wires.

UPCAST®-produced oxygen-free copper is a single-phase material containing only 1–3 ppm of oxygen. The UPCAST® process delivers the cast product directly at its final size without any hot rolling, eliminating the risk of rolling-induced inclusions and minimizing the thickness of the surface oxide layer. These characteristics give UPCAST® oxygen-free copper rod superior ductility along with excellent electrical conductivity.

UPCAST® copper rod is ideal for all electrical applications and has become the preferred feedstock for processes where ductility and surface quality are critical. It is especially well-suited for fine and multi-wire drawing, where high ductility is essential, and for enamel wire production, where an exceptionally smooth surface finish is required.

UPCAST® Tube

A shortcut
in production

The UPCAST® SGTube™ line produces thin-walled copper tubes with a grain structure that allows the cast tube to be directly processed using tube drawing machines. Since the cast tube is already close to the final product size, SGTube™ eliminates several costly and time-consuming steps required in conventional tube mills. The choice of the cast tube size depends among other things – on the size of the final tube product.

SGTube™ is primarily used for casting phosphor-deoxidized (DHP) copper tubes, which are widely used in sanitary, industrial, and air conditioning & refrigeration (ACR) applications. However, the process is not limited to DHP copper and is also suitable for other copper grades and copper alloys.

UPCAST® Alloys

UPCAST® – a versatile process for production of pure metals and alloys

The demand for alloyed coppers and copper alloys continues to grow, with new applications emerging rapidly. While the majority of UPCAST® units produce oxygen-free copper rod and SGTube™, the process is also highly adaptable for casting a wide range of non-ferrous materials.

UPCAST® technology enables the production of various copper alloys for diverse applications. For example, brasses and nickel silvers are commonly used in zip fasteners, while tin and phosphor bronzes are essential components in mobile phones. Silicon bronze and brass are well-suited for high-quality screws. Copper magnesium is widely used for grooved contact wires in high-speed trains, automotive wire harnesses, electrical and electronic connectors, and connector wires.

GreenerCast™ and Circular Economy

Always green. Now greener

UPCAST® technology has always been an environmentally friendly process, requiring only electricity, compressed air, and cooling water to operate. However, being inherently green does not mean it cannot become even greener.

While the direct environmental impact of UPCAST® technology is minimal, our focus has been on reducing indirect effects, particularly energy consumption, which is both an environmental and financial concern. To address this, we have developed GREENerCAST™ technology, a series of innovations that optimize efficiency and sustainability, including:

  • Double-loop inductors for improved energy utilization
  • Furnace linings designed to reduce heat loss, available in both traditional brick and PreCast element options
  • Stepless power control using fast-switching transistors
  • Enhanced capability to use clean copper scrap as raw material

UPCAST® technology supports the use of clean electrolytic-origin scrap, including OFHC and ETP copper scrap, either blended with cathodes or as a 100% scrap-fed input. This capability enables both in-house and external recycling, aligning with circular economy goals while also reducing raw material costs.

Energy for UPCAST® plants can come from green sources, as the process requires no fossil fuels for melting, holding, or any other operational activities. Achieving sustainable energy savings requires a combination of technologies working in synergy. GREENerCAST™ represents this integrated approach, incorporating both equipment and operational advancements to minimize energy consumption in the UPCAST® process.

From a global perspective, the ability to recycle efficiently is a key contributor to the GREENerCAST™ objectives, offering both environmental and financial benefits. Additionally, the use of renewable energy leads to a significant reduction in CO₂ emissions, further enhancing sustainability. This comprehensive strategy improves both the environmental footprint and the bottom line, reinforcing UPCAST® technology’s commitment to a greener future.

R & D

Continuous product and process development

Being a market leader is not just about the number of UPCAST® casting lines delivered — it’s about ensuring that every line is built with high quality and the latest technology. Ongoing collaboration with customers and industry partners drives future innovations, ensuring that UPCAST® remains at the forefront of continuous improvement.

At the heart of our research and development efforts is the UPCAST® Pilot Plant, which features two dedicated casting lines for testing and refining equipment, products, and processes.

Our primary focus is on adding value for customers, whether through greater efficiency, cost-effectiveness, ergonomics, environmental sustainability, or supply chain security. To achieve these goals, we conduct continuous trials at the Pilot Plant, including:

  • Testing new alloys
  • Enhancing rod and tube cast products
  • Developing improved or alternative process materials
  • Exploring new manufacturing methods

In addition, we produce sample materials that customers can evaluate and test in their own processes to ensure quality and performance. Our laboratory services in Pori provide further support for material analysis and development.

We are always open to collaboration and development support, whether at our Pilot Plant or at customer facilities. If you have ideas or specific needs for future innovations, we encourage you to reach out to us!