Continuous Casting Equipment
Copper Flat Bar Casting Line That Runs at Twice the Industry Rate
Upward continuous casting for oxygen-free copper flat bar profiles — the primary feedstock for busbar, electrical conductor, and current-carrying applications. Our patented S-type crystallizer geometry delivers 120 mm/min withdrawal speed versus the 60 mm/min of standard equipment.
2×
Output per shift vs. standard crystallizer
Oxygen-free
Grade — melt never exposed to air
Equiaxed
Grain structure — less cracking on punching & bending
The production case
Why casting speed and grain structure determine your per-tonne economics — not just nameplate capacity.
| Parameter | Conventional Crystallizer | Mivo Patented Crystallizer |
|---|---|---|
| Max casting speed | ~60 mm/min | 120 mm/min |
| Output per 8-hour shift (220×12 mm) | ~28.8 m | ~57.6 m |
| Grain structure | Columnar — crack-prone during punching & bending | Equiaxed — uniform, stable grain boundaries |
| Surface finish | Variable — higher rework frequency | Consistent — lower scrap rate per tonne |
| Alloy compatibility | Typically single-grade | Multi-grade via adjustable cooling parameters |
| Vendor coverage | Crystallizer only | Full line: furnace → crystallizer → traction → coiling |
* Shift output calculated at continuous run on a single-strand 220×12 mm reference configuration. Multi-strand and larger cross-sections configured per project.
How the line works
Cathode copper enters the induction melting furnace at one end. Molten copper flows into the holding furnace where temperature and composition are stabilised before it reaches the graphite die inside the crystallizer. As the copper solidifies upward through the die, the traction unit withdraws it at a continuous, PLC-controlled rate. The finished flat bar profile is cut to length and stacked in bundles — or, for narrow strip profiles, coiled onto a take-up reel.
The critical difference is in the crystallizer. Mivo's S-type water channel geometry circulates cooling water through a path that maximises the temperature gradient at the solidification front. This drives faster withdrawal without sacrificing grain quality — the copper solidifies in a controlled equiaxed pattern rather than the long columnar crystals produced by simpler straight-channel designs. The result is a flat bar profile with uniform grain boundaries that resists cracking during downstream punching, drilling, and bending operations.
Equipment Gallery
Technical Specifications
| Parameter | Value |
|---|---|
| Cross-section | Flat bar — custom width × thickness, specify on enquiry |
| Casting Speed | Up to 120 mm/min (patented crystallizer, 220×12 mm ref.) |
| Annual Capacity | Configured to project requirement |
| Furnace Capacity | Per project specification |
| Strand Count | Single or multi-strand — per layout |
All parameters are project-specific. Send us your cross-section and annual tonnage target and we'll return a configuration proposal within 1 business day.
Line Components
- Induction melting furnace
- Patented graphite crystallizer — S-type water channel geometry
- Traction and coiling system
- PLC process control
- Closed-loop water cooling system
- Modular design for capacity expansion
Typical Downstream Applications
The flat bar profiles produced by this line are primarily used in the following applications by our customers:
- Busbar for power distribution switchgear
- Busbar for EV battery packs & energy storage
- Conductor rail for data center power distribution
- Traction conductor for railway systems
- Winding conductor for industrial transformers
On-site installation & commissioning
Mivo engineers travel to your facility for installation supervision, parameter setup, and operator training. Remote diagnostics are available post-handover. We don't hand you a manual and leave — the line is commissioned to your actual production target before we close the project.
Note: Remote installation support is available for customers who cannot accommodate on-site visits. Discuss your situation when you request a quote.
Get a configuration proposal
Tell us your cross-section range, annual tonnage target, and feed material (cathode / scrap). We'll return a line configuration and preliminary cost estimate within 1 business day.
Get ROI & Pricing Talk to Our Lead EngineerResponse within 1 business day. We need: cross-section (width × thickness mm), annual tonnage, and feed material type.
Get in touch
Ready to specify your busbar casting line?
Send us your cross-section range and production target. Our engineers will return a configuration, preliminary specifications, and a cost estimate — within 1 business day.