LENAAL Boosts Production Uptime by up to 50% with Monitizer | REFILL MONITOR

Scaling up with smart furnace monitoring 

Polish high pressure die caster, LENAAL Sp. z o.o. Sp. k., has connected all aluminum cells at its 10,300 m² production facility to digital solution - Monitizer | REFILL MONITOR. This latest roll out is part of an ongoing investment strategy to boost operational efficiency and production capacity. 
 

"We’ve seen between 25-50% more production uptime as a result. REFILL MONITOR has made a big difference to our operations – and it’s so easy to use."

Jakub Pomajda, Process Engineer, LENAAL

Automating refill monitoring for maximum efficiency 

REFILL MONITOR is compatible with any make of holding/dosing furnace. It continuously checks dosing furnace fill levels against the metal consumption of the die casting process. It shows real-time insights, indicating when to refill, which alloy to use, and the required weight of metal-helping operators avoid downtime and maintain seamless production.

 

From pilot to full rollout – Why LENAAL made the investment

Following a successful pilot in 2023, LENAAL has gradually added more lines to the digital furnace monitoring system. This, together with investment in two additional casting cells fed by new Westomat dosing furnaces from StrikoWestofen has resulted in a 65% increase in production output. 
Now all 13 Westomat furnaces - and the fully automated horizontal cold chamber die casting cells they feed – are digitally monitored, further efficiencies are anticipated. 

LENAAL relies on 3 StrikoMelter furnaces to ensure a constant supply of high-quality liquid aluminum for casting a range of parts for the automotive industry – focusing predominantly on the EV sector. 

Cutting downtime, increasing uptime by up to 50%

Previously operators had to check furnace levels individually – a time-consuming process that sometimes led to furnaces running dry and causing production delays. 

“We don’t have that problem anymore. We’ve seen between 25-50% more production uptime as a result.” says Jakub Pomajda. 



A powerful, user-friendly efficiency tool

“I like everything about REFILL MONITOR, it has made a big difference to our operations. Best of all, it is very easy to use. As an engineer, everything I need for checking on daily tasks is right there in a simple dashboard so that I can report to my manager. It’s ideal for a busy die casting facility like ours.”

Jakub Pomajda, Process Engineer, LENAAL

In addition to dashboards used by the melting department team to monitor fill levels, LENAAL’s engineers also use the system to track and compare KPIs from each line, including furnace temperatures, dosing cycles completed over specific time frames, and average metal dosed per cycle. 

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