Granulated Coatings (Clone for 2026 Launch)

A New Generation of Foundry Coating Technology

Refractory coatings play a critical role in the foundry industry by improving the mold–metal interface, enhancing surface finish, and preventing metal penetration and chemical reactions. These coatings are widely used across iron, steel, and other high-temperature alloy casting processes.

Traditionally, refractory coatings are supplied as premixed liquids or pastes, requiring significant logistics, storage, and preparation effort.

Granulated Coatings introduce a new approach—enabling coatings to be prepared fresh, on demand, while significantly reducing freight, handling, and storage requirements

A Disruptive Innovation in Coating Delivery

Granulated coatings represent a new form of refractory coating supplied in a moist, granulated form that is mixed with water on-site to produce a ready-to-use slurry.

Unlike traditional premix coatings that ship large volumes of water, granulated coatings deliver a concentrated product prepared only when needed. This improves consistency while reduces logistics costs and operational complexity.

By separating transportation from preparation, foundries gain the ability to produce coating exactly when required—without sacrificing performance.

Key Benefits for Foundries

Granulated coatings deliver clear operational and economic advantages—fresh, on-demand preparation at the point of use for consistent performance, lower freight costs by eliminating shipped water (one truckload can replace ~two premix loads), and reduced handling with less material to move and store. Logistics are simplified by eliminating returnable totes, tanker endorsements, and cleaning/return requirements, while also supporting a lower carbon footprint through reduced transportation volume and packaging. Granulated coatings also offer up to one year of shelf life and easier housekeeping, with quick, clean spill recovery.

Operational Advantages

Granulated coatings improve process efficiency with faster preparation (about one-third the time required to homogenize premix) and improved suspension stability by eliminating settling during transport and storage. Their concentrated format also reduces warehouse space requirements, and preparation can be fully automated to improve consistency while reducing labor. In addition, high-efficiency packaging—including future super sack formats—can further reduce handling and packaging waste.

Validate Performance. Eliminate Risk.

HA-International’s Demo Granulated Preparation Unit (DGPU) allows foundries to experience granulated coating technology in real production conditions—before committing to full-scale implementation.

Designed for rapid deployment, the DGPU enables evaluation of performance, process compatibility, and operational benefits with minimal disruption.

The DGPU is more than a trial—it’s the first step toward modernizing your coating process. Once validated, operations can scale to full production using the Granulated Preparation Unit (GPU)—designed to meet the demands of high-volume foundries.

From Semi-Manual to Fully-Automated

The Granulated Feed Hopper (GFH) is the material handling component of the system, delivering consistent, controlled feed of granulated coating into the mixer. The same hopper design is used for both trials and full-scale production—ensuring seamless scalability from validation to implementation.

Together, the GFH and mixing unit form a complete, integrated preparation system designed for both mobility and scale. The system is compact enough for on-site trials, yet robust enough for full production. With PLC-controlled operation, minimal utility requirements, and reduced manual handling, it delivers consistent performance while maximizing efficiency, safety, and throughput.