Other Equipment

WORSWICK AUTOMATED LEAD DROSS REMOVAL SYSTEM

Engineered for Efficiency, Safety, and Operator Ergonomics

In addition to our extensive portfolio of non-ferrous metal casting systems, WORSWICK has developed a purpose-built, automated dross removal machine designed to dramatically reduce operator strain, enhance workplace safety, and increase process consistency during surface dross removal operations in melting pots.

Background and Problem Statement

Traditional dross removal from lead bath surfaces has long been a labor-intensive, two-person operation involving hazardous manual scraping and skimming techniques. Historically, one operator would drag floating dross across the molten lead surface, while the second would extract the dross using a manually handled spoon and deposit it into a waste bin via a pivoting "drossing horse." This exposed workers to high heat zones, repetitive motion stress, and elevated risk of back injuries—conditions that were both unsafe and ergonomically unsustainable.

Automated Dross Removal Solution

The WORSWICK Dross Removal Machine eliminates manual raking and skimming by performing a fully automatic, programmable drossing cycle. When used in conjunction with low-speed molten metal agitation (either by mechanical stirrer or pot rotation), the machine provides highly effective surface cleaning with minimal operator involvement.

System Overview and Operation

  • Cycle Control:
    The drossing sequence is governed by a programmable timer-based logic, allowing cycle duration to be tailored to pot size, alloy type, and dross accumulation rate. Once initiated, the system autonomously executes the scraping and lifting motion profile.

  • Cycle Completion Alert:
    At the end of each drossing cycle, an audible and/or visual alarm is triggered, summoning the operator to inspect the pot. If no further action is required, the alarm self-resets, and the system returns to its home/start position.

  • Supervisory Role Only:
    The operator's function is reduced to a supervisory role—initiating the cycle, verifying dross removal completeness, and reactivating the unit as necessary—eliminating direct contact with the molten surface.

Design and Structural Features

  • Cantilevered Mounting with Central Pivot:
    The machine is supported via a cantilevered swing-arm structure with a central pivot point, allowing:

    • Full rotational clearance away from the pot for maintenance or manual access

    • Easy positioning between multiple pots using modular stands

    • Vertical lifting and relocation via crane, using integrated three-point lifting lugs

  • Multi-Pot Integration:
    Ideal for facilities with multiple melting pots and low drossing frequency, a single unit can service multiple locations, reducing capital expenditure and footprint.

Field Performance and Industry Adoption

  • Over 100 units sold worldwide, with a significant number of repeat orders from both primary and secondary lead processing plants.

  • Machines have proven their reliability in continuous production environments, where improved operator safety and process consistency are paramount.

 drosser