Case Study: FeSi Inoculant for a South American Foundry

Reliable supply of 2‑10mm ferrosilicon inoculant, SGS certified 76.26% Si. How we helped a casting plant improve quality and reduce defects.

The Challenge at a Major Foundry (South America)

The client produces ductile iron castings for heavy machinery. Their previous FeSi inoculant (2‑10mm) had inconsistent silicon (72‑74%) and higher sulfur, causing chill problems and variable nodularity.

  • Inconsistent Si → unstable inoculation, hardness variations
  • Sulfur peaks up to 0.07% → more Mg consumption, dross formation
  • Oversize & fines → poor dissolution & yield loss
  • Need for a reliable partner with strict size control and purity

✅ Our solution: Foundry‑grade FeSi 75% inoculant

Supplied 2‑10mm ferrosilicon with SGS certificate:

Silicon (Si) 76.26% >74% req.
Sulfur (S) 0.02% req. ≤0.04%
Phosphorus (P) 0.027% req. ≤0.05%
Size 2‑10mm (≥92%)
Carbon (C) 0.08%

⚡ Real foundry‑floor results

-14%
inoculant consumption per ton
+7%
nodule count (better ductility)
-31%
dross & slag defects
+22%
longer ladle life (less S)

⚡ Exceeded foundry specifications

✅ Si 76.26% (vs spec 74% min) ✅ S ≤0.003% (vs ≤0.04%) ✅ P 0.022% (vs ≤0.05%) ✅ 2‑10mm 96% (spec 90%) ✅ SGS certified
Step 1/6

Inoculant Raw Material Sorted

We selected high‑purity FeSi 75% crushed lumps, then carefully screened to 2‑10mm fraction at our Anyang plant. Oversize and fines removed to ensure uniform dissolution in the foundry.

🔍 Client requirement: Si ≥74%, 2‑10mm (90% min)
📊 Our internal check: Si 76.0%, S ≤0.003%, P 0.022%, size 2‑10mm 96%
Step 2/6

SGS Inspector Sampling

Independent SGS inspectors attended our warehouse, took representative samples from the prepared 2‑10mm lot, and sealed them in the presence of our QC team.

Step 3/6

SGS Certificate Issued

Lab analysis confirmed: Si = 76.26% (well above 74%), S = 0.02%, P = 0.027%. The certificate was sent to the client before shipment, giving full confidence.

Step 4/6

Packing & Container Loading

Material packed in 1MT big bags with inner small bags, then loaded into 20' containers under SGS supervision. Seal numbers recorded and photos taken for each container.

Step 5/6

Ocean Freight to South-America

Containers shipped from Xingang to the main South American port. Full documentation (BL, SGS, packing list) sent ahead for smooth customs clearance.

Step 6/6

Foundry Approval & Repeat Order

After the first trial, the foundry reported: consistent silicon recovery, improved graphite nodularity, and less dross. They sent an email praising the product and placed a repeat order for the next quarter.

“The 76% Si inoculant performed excellently – very consistent and clean.” – Mr. J. M., Foundry Supervisor

📊 The numbers that count (foundry edition)

2.26%
extra Si above spec
50%
lower sulfur (vs 0.04% max)
46%
lower phosphorus
92%
2‑10mm fraction (min 90%)
“We’ve been using Bright Alloys’ FeSi inoculant for six months. The silicon content is always above 76%, sulfur extremely low — our casting rejection rate dropped by 18%. It’s now our standard supplier.”
— Metallurgical Manager, South American Foundry

Precise size + high purity = predictable casting quality

This South American foundry case proves: when you order FeSi inoculant from Bright Alloys, you receive material well above specification (76.26% Si) with tight size control. Our independent SGS checks and full transparency let you focus on making sound castings — at lower cost. Join foundries across the globe that trust us.

Request similar inoculant quote View FeSi inoculant specs

Why foundries in South America trust Bright Alloys

🔬
Every batch SGS/BV tested
📏
Precise 2‑10mm sizing (no fines)
🌍
20+ countries · 100+ clients including foundries
💳
L/C, T/T, flexible terms

Get the same foundry‑grade FeSI trusted in South America

Request a quote + free SGS report sample for your next inoculant order.

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