Master Alloys / 07.13.2021

How are Next-Generation Master Alloys Different from Traditional Master Alloys?

How are Next-Generation Master Alloys Different from Traditional Master Alloys? - Image

Master alloys are well known for offering consistent and reliable chemistry. Because they typically melt faster and at a lower temperature than pure metals, master alloys also tend to cut down on both time and costs associated with the sourcing of virgin materials. In addition to introducing those greater efficiencies, master alloys that utilize post-industrial base materials communicate to your customers that you are planning for a greener future. 

There’s no shortage of master alloys available today. With more and more companies championing their latest master alloy solution, how do purchasing departments make the right decision?  

Purchasing managers are always facing increased pressure to increase production speed while managing costs and reducing costly errors. Shapiro’s next-generation master alloys aren’t just designed to make your stakeholders pat themselves on the back for implementing sustainable manufacturing practices. Our master alloys offer organizational improvements and better workflow efficiency, increasing your bottom line alongside reducing your carbon footprint. 

What are the Downsides of Traditional Alloying Agents?

We continue to encounter many shops that still opt to blend their own alloys on-site. For some applications, that still may prove to be cost effective, particularly if you have the resources to execute the process in-house. Even if you have adequate staffing (of metallurgists, engineers, skilled furnace technicians, etc.), virgin materials introduce other barriers that master alloys can address. 

“Going green” isn’t just the stuff of feel-good marketing campaigns anymore, and the public is well aware of what greenwashing looks like. So, therefore, are your customers. The industry is steadily heading into a future defined by sustainable manufacturing. The combination of environmental regulations and public perception will put real pressure on our industry to reduce its carbon footprint severely, if not entirely. 

The sourcing of virgin materials (even if you have the skill set and talent internally to mix them) is an environmentally scarring process from end-to-end. Strip mining can destroy natural ecosystems and leave behind forever chemicals in the watershed. The smelting and processing of those virgin metals is a major contributor of CO2 and other greenhouse gases. Numbers vary, but most research cites that aluminum production creates anywhere from 11 to 17 metric tonnes of CO2 materials per tonne of aluminum. 

Then there’s the localized costs passed on to your facility when you blend your own alloys in-house. You need to source multiple materials, prices for which can vary wildly, depending on supply chain issues and naturally occurring shortages. You also take on the additional risk of on-site storage and handling of raw materials. 

When you combine those raw materials, the accuracy of that entire process sits in the hands of your internal team. With varying melt rates for different materials, any missteps could result in some serious quality issues with the end-product. The last thing you want to find out is that there have been failure issues with your parts or products. 

How are Shapiro’s Aluminum Master Alloys Different from Traditional Master Alloys?

We have a long history, dating back to the turn of the 20th century, of working with the industrial sector and foundries. We’ve developed greener alternatives to master alloys, utilizing 100% recycled post-industrial non-ferrous metals. 

As such, our alloys are created to reduce error rates and simplify the alloying process for all of our stakeholders. Our pre-mixed metals are engineered here and arrive to you as a furnace ready product. The rigorous certified analysis that we apply to our custom products cuts down on the opportunity for error, putting our expertise in the literal hands of your teams. 

Consistent melt rates improve metal recovery for better throughput, reducing your overall production cycles. Our alloys use less storage space and require less handling than virgin metals, and are available in larger sizes (1,000-to-2,000-pound sows). We utilize a greater ratio of aluminum to the alloying agents (silicon or magnesium) for better material consistency and value.

What are the Benefits of Our Master Alloys to Your Team?

How do these material advantages better equip your team and your production floor to save time and money, in addition to creating better parts and products?

Environmental

Using non-virgin aluminum greatly reduces your carbon footprint and creates a closed loop for production in the future. Utilizing scrap metal cuts down on water usage by 40%, mining waste by 97%, and saves up to 92% of the energy usage.

Increased Efficiency

By reducing the reliance on internal labor, you’re cutting down on the furnace operator’s need to add the correct amount of blocks at the right time. That frees up staff internally to run other equipment. It also introduces fewer opportunities for error. 

Cost

With increased throughput, you experience less volume loss from the production process itself, giving you more parts from a single run. The increased amount of aluminum per block results in improved consistency and a steep reduction in material loss. Alloying agents can also be difficult to source. Our alloys are a far more reliable option that reduce headaches and time for your purchasing teams. You can also reduce your reliance on internal expertise, reducing pressure on your recruiting process. 

Summing Up: Why Shapiro’s Next-Generation Master Alloys?

We’ve worked for generations to design, implement, and optimize sustainability programs throughout the country. Our next-generation sustainable additives allow you to deploy recycled content in your manufacturing process, with the ensured security of scientific reliability and certainty. We independently test all of our materials before they are converted into master alloys, arriving to you furnace-ready. From our 10 ISO-certified processing facilities across the United States, we leverage a robust, proprietary supply chain for metal materials around the clock, proactively sourcing materials in demand by our—and your—customers. 

Ready to bring our next-generation technology into your production process? Contact us today to speak with a Shapiro Master Alloys expert.