Precision Castings for Waste-to-Energy Boiler Efficiency
With over 12 years of experience serving the waste-to-energy sector, Boro Foundry understands the importance of durability, precision and supply continuity in maintaining boiler efficiency. We supply high-integrity castings for critical boiler components — helping reduce downtime and extend operating life.
Historically, the industry has suffered from low-quality castings, leading to costly failures and unplanned outages. That’s why our castings are produced under strict control of chemical composition, machining tolerances, and batch traceability — giving maintenance teams peace of mind when replacing parts.
Flexible Redesign for Improved Performance
Unlike many OEMs that only offer standardised components, Boro Foundry works directly with maintenance and operations teams to redesign cast parts for improved performance and adaptability. Whether you’re addressing boiler movement, component misalignment or general wear, we can assist in optimising geometry and material selection.
Grate Bar Castings & CNC Machining Investment
In 2015, we invested in a twin-table horizontal boring machine, dedicated to machining grate bars in high volumes — helping us meet cost targets and shorten lead times for our clients. From casting through to final machining, we offer an end-to-end supply solution for boiler spares and wear components.
We’ve supported multiple redesign projects, including:
120mm & 128mm grate bar upgrades:
Redesigned with customers to reduce core usage and improve flow
Baumgarte bar improvement:
Material change and optimised machining path for better efficiency
Middle bar conversion:
Replaced a fabricated unit with a single-piece cast design for strength and longevity
Circular Solutions: Casting Buyback Programme
To support sustainability and reduce costs, we also offer a used casting buyback scheme. Old castings can be returned and credited against new production — often using the same or equivalent material grade. We manage all logistics, including collection and weight certification, helping you streamline your casting supply chain.
FREQUENTLY ASKED QUESTIONS
What types of castings do you supply for waste-to-energy plants?
We specialise in critical boiler components such as grate bars and wear parts. These are engineered to withstand high temperatures and continuous operation, helping maximise boiler efficiency and uptime.
Can you redesign existing components to improve performance?
Yes. Unlike many OEMs who only supply standard parts, we work directly with maintenance teams to redesign castings — optimising geometry, material selection, and machining paths to extend service life and improve efficiency.
Do you offer machining as well as casting?
Absolutely. In 2015 we invested in a twin-table horizontal boring machine specifically for high-volume grate bar machining. This allows us to provide a full end-to-end solution — from casting to final precision machining.
How do you help reduce costs for replacement castings?
We operate a casting buyback programme. Customers can return used castings, which we credit against new production. This circular approach reduces costs, simplifies logistics, and supports sustainability goals.
How do you ensure reliability in boiler components?
Our castings are produced under strict controls for chemical composition, machining accuracy, and full traceability. This ensures consistent quality, reducing the risk of downtime and costly unplanned outages.
