James Tomkinson* discusses a dross pressing system which, after recent trials with an aluminium producer in North America, delivered a notable increase in recovered aluminium.

RIA Cast House Engineering, headquartered in Leipzig, Germany, continues to push the boundaries of aluminium furnace technology with its In Furnace Dross Pressing (IFDP) system.

The company, already a trusted global supplier with more than 90 precision, rail mounted Furnace Charging and Skimming Machines installed worldwide, is now preparing to deliver its ninth skimming unit equipped with IFDP.

With installations spanning three continents and positive feedback from recent trials, RIA’s patented IFDP technology is emerging as a new industry benchmark for efficiency, sustainability, and metal recovery.

The company has built its reputation on delivering highly reliable and precise furnace solutions to aluminium producers around the globe.

The company’s engineering excellence and strong repeat customer base demonstrate a proven ability to combine mechanical innovation with operational practicality.

In 2019, RIA began development of its patented IFDP system, a new approach to dross management designed to improve both furnace efficiency and metal yield.

Despite the challenges presented by the global pandemic, including limited access to trial sites, RIA persevered through several years of testing and refinement.

Today, those efforts have culminated in a fully operational technology that has already demonstrated measurable benefits during recent customer trials in North America.

Proven results in trials
A major global aluminium producer recently completed an IFDP trial with outstanding results.

Compared with standard furnace operation, the IFDP system achieved a clear improvement in overall gross recovery during the 2025 trial period.

The process delivered a notable increase in recovered aluminium, reducing the amount of scrap required for furnace charging.

In today’s global market, where scrap prices and availability remain volatile, this represents a valuable advantage for any casthouse operation.

By retaining more liquid aluminium within the furnace, the IFDP system minimised metal losses to dross and reduced the need for reprocessing, lowering energy consumption, cutting CO2 emissions, and driving meaningful reductions in overall production costs.

Cleaner, cooler, and more efficient
The benefits of IFDP extend beyond yield improvement.

The process works by pressing and compacting dross while still inside the furnace, using specially engineered IFDP blades that remain clean and effective throughout operation.

This action not only retains more aluminium within the furnace but also ensures that the dross leaving the sill is less reactive and cooler.

Trials showed that dross processed with the IFDP system often cooled to below 320°C by the time it reached the dross pan, a substantial reduction compared to conventional skimming.

This rapid cooling minimises further oxidation, preserving valuable metal units that can be recirculated into production rather than lost to secondary processing.

In practical terms, this means operators can expect:
Higher metal recovery through reduced aluminium loss.
Reduced secondary dross processing volumes and costs.
Enhanced workplace safety due to cooler, more stable dross handling.

A global step forward
Following the successful completion of the trial, RIA is moving forward with installations of its IFDP equipped skimming machines across three continents.

The ninth IFDP unit is currently under construction, reinforcing RIA’s commitment to supporting both primary and secondary aluminium producers with modern furnace solutions.

This latest advancement builds upon RIA’s long-standing expertise in automated cast house equipment.

The company’s precision engineered machines, many of which are in continuous operation at major aluminium facilities worldwide, are known for their durability, accuracy, and ease of integration into existing plant operations.

Shaping a more sustainable future
In an industry under pressure to improve efficiency and reduce waste, the IFDP technology represents a meaningful step toward more sustainable aluminium production.

By improving metal recovery, reducing oxidation, and minimising dross reprocessing, the IFDP system not only enhances profitability but also reduces the environmental footprint associated with remelting operations.

As RIA continues to expand deployment of this technology, the company is reaffirming its position at the forefront of cast house innovation, driving improvements in performance, sustainability, and global furnace operations.

*Sales and Marketing Manager, Ria Casthouse, https://www.ria-casthouse-engi...