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With over 70% of castings produced through sand moulding, the foundry industry faces twin challenges—high dependency on fresh silica sand and rising costs of disposal. For every tonne of casting produced, nearly an equal amount of sand is consumed and discarded, leading to escalating costs, environmental stress, and sustainability risks.
Recognizing this, Rhino Machines partnered with FATA Aluminum (Italy) in 2013 to bring advanced green sand and thermal reclamation technology to India. Rhino set up pilot plants in 2015 (S1 Mechanical Reclamation) and 2017–18 (S3 Mechanical–Thermal–Mechanical Reclamation) to establish proof of concept, validate techno-commercial feasibility, and study performance across different sand-binding processes.
These pilots demonstrated:
50% reduction in new sand use in production foundries.
Viability of hybrid mechanical + thermal processes for higher recovery.
Better casting finish and reduced rejections when using reclaimed sand.
Lower emissions and transport footprint, addressing ESG priorities.
Sand Reclamation Plant
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S1 – Mechanical Reclamation (Green Sand)
Recovers sand through scrubbers, blowers, declusters, and dust extraction, reducing fresh sand consumption. -
S2 – Thermal Sand Reclamation
A highly efficient vertical furnace (550–750°C) for chemically bonded and green sand, with direct heat recovery and in-built sand cooling. -
S3 – Mechanical–Thermal–Mechanical Reclamation
Hybrid process recovering 80–85% silica sand, reducing carbon footprint and addressing green sand recycling challenges.
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With its own facility as a living lab, Rhino provides industry with a tested, community-centric roadmap for setting up CFCs—turning reclamation into a shared resource for sustainable growth.