In a major, high-value project – the second at this particular plant in Mexico – NUTEC Bickley will supply a 125m-long tunnel kiln to one of the world’s leading advanced ceramics manufacturers.
We are industrial furnace manufacturers, our industrial heat treatment furnaces can be provided for a wide range of temperature ranges and a wide variety of applications.
With Fiber lined sections using the patented “Jointless System®” with special design to compensate for the fiber shrinkage and the most advanced heat recovery systems with recuperative burners performing fuel savings from 10% up to 50% vs cold air systems.
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Nutec Bickley provides heavy duty moving hood furnaces for the heat treatment process (Normalizing, Annealing, stress relieving and others) of steel forgings and castings and large steel plate formed parts. These furnaces are an excellent alternative for heavy loads placed in several stationary bases, and moving hood furnaces are travelling to the required heating station.
Each of our kilns and furnaces are designed based on the needs of the client. We do not have standardized models since we understand that each company has different operational requirements, so we adapt our technology to your specific needs.
We have a fully equipped laboratory with advanced combustion, monitoring and control systems. This allows us to perform a wide range of scale tests and virtual design as a primary part of our service. Our team pre-assembles all our furnaces and kilns and in the case of smaller ovens we can also send it fully armed, saving important downtime to our customers.
As industrial furnace manufacturers, we have a strict quality control protocol (QA) for our equipment once they have been assembled, which translates into greater operational reliability and compliance with safety regulations.
There are many types of industrial furnaces, each designed to meet specific heating and material processing requirements in various industries. Furnaces are generally classified by their heating method, design, and application.
1.1. Combustion or Fossil Fuel Furnaces:
These use fuels such as natural gas, oil, or coal to generate heat. They are common in applications requiring high temperatures.
Example: Metal melting furnaces, ceramic kilns.
1.2. Electric Furnaces:
These generate heat through electrical resistances or induction. They are used when precise temperature control is required or in environments where combustion is not ideal.
Example: Induction furnaces, electric arc furnaces.
1.3. Hybrid Furnaces:
These combine combustion and electric heating to leverage the advantages of both systems.
2.1. Batch Furnaces:
These process materials in individual loads or batches. Materials are loaded, processed, and unloaded before starting a new cycle.
Example: Tempering furnaces, annealing furnaces.
2.2. Continuous Furnaces:
These operate continuously, allowing materials to enter and exit the furnace while the process is underway.
Example: Conveyor belt furnaces, tunnel kilns.
3.1. Heat Treatment Furnaces:
Used to alter the physical and mechanical properties of materials, such as metals.
Example: Annealing furnaces, tempering furnaces, normalizing furnaces.
3.2. Melting Furnaces:
Designed to melt materials such as metals, glass, or plastics.
Example: Crucible furnaces, electric arc furnaces.
3.3. Drying Furnaces:
These remove moisture or water from materials such as wood, ceramics, food, or chemicals.
Example: Industrial drying ovens, curing ovens.
3.4. Sintering Furnaces:
Used in sintering processes to compact powdered materials with heat without reaching fusion.
Example: Ceramic or powder metallurgy sintering furnaces.
3.5. Calcination Furnaces:
Applied in chemical processes to decompose compounds, remove water, or produce structural changes.
Example: Rotary kilns, fluidized bed kilns.
3.6. Glass Furnaces:
Specialized in glass manufacturing and treatment.
Example: Float glass furnaces, glass annealing furnaces.
3.7. Food Industry Furnaces:
Used for baking, roasting, or drying food products.
Example: Industrial bakery ovens, dehydration ovens.
4.1. Atmospheric Furnaces:
Operate under normal atmospheric conditions without specific control of the internal environment.
4.2. Controlled Atmosphere Furnaces:
Use specific gases (such as nitrogen, hydrogen, or argon) to prevent oxidation or undesired chemical reactions.
Example: Vacuum furnaces, inert gas furnaces.
4.3. Regenerative or Recuperative Furnaces:
Recover heat from the combustion process to improve thermal efficiency.
5.1. Low-Temperature Furnaces:
Temperatures below 400°C.
Example: Drying or curing ovens.
5.2. Medium-Temperature Furnaces:
Temperatures between 400°C and 1200°C.
Example: Heat treatment furnaces.
5.3. High-Temperature Furnaces:
Temperatures above 1200°C.
Example: Metal melting furnaces, sintering furnaces.
Metals: Electric arc furnaces, induction furnaces, annealing furnaces.
Ceramics: Tunnel kilns, roller kilns.
Chemicals: Calcination kilns, rotary kilns.
Glass: Glass melting furnaces, annealing furnaces.
Food: Bakery ovens, drying ovens.
In summary, the variety of industrial furnaces addresses the specific needs of different industrial sectors, manufacturing processes, and material types. The choice depends on the type of material, temperature range, production speed, and required energy efficiency.
Industrial furnace temperatures vary depending on their design and application. Most heat-treatment furnaces typically operate between 1,000°F and 2,400°F (about 538°C to 1,315°C). Certain specialized or high-temperature furnaces, like those used for melting steel or processing advanced ceramics, can reach up to 3,000°F (about 1,650°C) or even higher.
The exact maximum temperature depends on the furnace’s construction, insulation, and intended use.
When purchasing an industrial furnace, you can expect a range of benefits that support both operational efficiency and overall profitability. Key advantages include:
Improved Product Quality
Consistent temperature control ensures uniform heating, reducing defects and improving the quality of treated materials.
Greater Energy Efficiency
Modern furnaces often feature advanced insulation, combustion systems, and heat recovery technology that help lower energy costs.
Enhanced Throughput and Productivity
Shorter heating and cooling cycles, along with automated controls, speed up production processes and reduce downtime.
Long-Term Cost Savings
While the initial investment may be substantial, efficient fuel usage and reduced maintenance can lower operating costs over the furnace’s lifespan.
Process Flexibility
Customizable furnace configurations accommodate various materials and processes, making it easier to adapt to changing production needs.
Reliable Operation and Safety
Modern designs include robust safety systems, ensuring stable performance and protecting both operators and equipment. By choosing the right industrial furnace, you can streamline production, improve quality, and realize significant returns on your investment.
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Custom furnaces for metals. Specifically designed around a certain application or product manufacturing process.
Standard equipment. Being mass produced, these furnaces are created to cover a broad spectrum of general purpose applications.
Custom furnaces for metals. Designed according to standards and international requirements for the heat source, combustion system, components, etc.
Standard equipment. These furnaces carry preset features with fewer adjustment options, which limits their flexibility and adaptability compared to custom furnaces.
Custom furnaces for metals. Due to the nature of their design, engineering, and manufacturing process, they may require longer lead times.
Standard equipment. Being mass produced, these furnaces are created to cover a broad spectrum of general purpose applications.
Custom furnaces for metals. These offer superior performance due to specific design, engineering, and manufacturing processes.
Standard equipment. Although their standardized design fits a broader spectrum of applications, they can offer reliable performance.
Industrial furnaces are used across various industries to heat, melt, or treat materials under controlled conditions. Typical applications include:
Heat Treatment: Processes such as annealing, tempering, and quenching to alter a material’s microstructure, improving strength or ductility.
Metal Processing and Melting: Melting raw metals or alloys, refining processes, and casting operations for sectors like automotive, aerospace, and construction.
Ceramics and Glass Production: Firing and shaping ceramic products, as well as softening and molding glass.
Chemical Processing: Drying or baking chemical substances, removing moisture, and facilitating chemical reactions at high temperatures.
These furnaces often feature advanced controls and systems to maintain precise temperatures and meet specific process requirements.
The lifespan of an industrial furnace typically ranges from 15 to 30 years, though actual service life varies based on factors like design, operating conditions, maintenance practices, and build quality. Regular inspections, prompt repairs can significantly extend a furnace’s operational life. Ultimately, well-maintained furnaces can remain reliable and efficient for decades before requiring major upgrades or replacement.
The most efficient type of furnace depends on the specific application, but regenerative and recuperative furnaces are often considered very efficient due to their heat-recovery capabilities. Here’s how they work.
Regenerative Furnaces: Use two (or more) chambers packed with a heat-absorbing material. Waste heat from exhaust gases is stored in one chamber while the other preheats incoming combustion air, then they switch. This process recycles heat and significantly reduces fuel consumption.
Recuperative Furnaces: Employ heat exchangers (recuperators) to capture waste heat from exhaust gases and preheat the incoming air or fuel. Although generally less efficient than regenerative systems, they still offer considerable energy savings compared to standard furnaces. When evaluating furnace efficiency, it’s also important to consider factors like material type, process requirements, insulation quality, and advanced controls—each of which has a major influence on overall energy use.
Industrial furnaces can operate on a range of fuels, depending on the design and application. Common fuels include:
Natural Gas – Widely used due to its availability, relatively low cost, and cleaner combustion compared to other fossil fuels.
Propane or LPG – Often used in regions without direct access to natural gas, providing a portable and cleaner-burning option.
Fuel Oil – Still employed in certain areas or industries where natural gas infrastructure is limited, although it generally has higher emissions.
Electricity – Electric furnaces use heating elements instead of burning a fuel; these are common in applications requiring precise temperature control or in locations prioritizing reduced emissions.
The choice of fuel typically depends on factors like cost, regional availability, environmental regulations, and the specific heat requirements of the furnace process.
Efficiency for industrial furnaces varies widely based on design, fuel type, insulation, and process requirements. In general, traditional furnace efficiencies can range anywhere from 50% to 80%. However, modern or upgraded furnaces—especially those equipped with regenerative or recuperative heat recovery systems—can achieve efficiencies of 85% or higher. Factors like proper maintenance, optimized operating conditions, and advanced controls also play a major role in overall efficiency.
Industrial furnaces and ovens both heat materials, but they differ in temperature range and intended applications:
Industrial Furnaces: Typically reach much higher temperatures (often 1,000°F/538°C or more) and handle more intensive processes like melting metals, heat treating alloys, or firing ceramics. They’re designed with robust insulation and controls to manage extreme heat conditions.
Industrial Ovens: Operate at lower to moderate temperatures, often under 1,000°F/538°C, making them well-suited for processes like drying, curing, baking, or preheating. They’re commonly used for applications such as paint curing, food processing, and other thermal treatments that don’t require extreme heat.
We serve multiple industries through the design, building and installation of combustion systems, thermal insulation and highly specialized industrial furnaces, kilns and ovens. We are focused on understanding our customers’ needs and supplying the best equipment at the most competitive price.
In a major, high-value project – the second at this particular plant in Mexico – NUTEC Bickley will supply a 125m-long tunnel kiln to one of the world’s leading advanced ceramics manufacturers.
Explore NUTEC Bickley's latest innovative project, a highly flexible, energy-efficient shuttle kiln for the European sanitaryware sector.
Industry leading manufacturer, specializing in rotary forging, metal spinning, and the flow forming of aluminum and other alloys into complex shapes.
We offer specialized technical support and advice to ensure that you choose the solution that best suits your needs. Fill out this form or contact us to talk to us now.
