Posted on 8th August 2017 by Paul King
Aluminium Bending – Croffles saving cash for factory was the focus when Euro‑Matic began supplying cover balls (also known as Croffles) to ABS in 2011. ABS, an aluminium bending factory producing window frames and structural supports, faced high heating costs. Their large bending tank needed to stay at 98 °C, an expensive and energy-intensive requirement.
By covering the tank with Croffles, ABS created a protective thermal layer. The balls float on the hot water, allowing level movement but dramatically reducing evaporation. As a result, ABS saved up to 90% of water loss and cut their heating bills significantly.
The question often arises: how long do Croffles last? ABS put this to the test. During a scheduled tank repair, they discovered their original clear 50 mm PP cover balls—six years old—still working, albeit slightly weighed down by degreaser residue. Most continued floating. Based on this, ABS ordered a fresh batch of clear PP cover balls with next‑day delivery to refill the tank and return operations to full capacity.
While the primary goal was to curb heat loss in aluminium bending, using Croffles provided other advantages. First, they limit steam escape from the tank. This maintained a safer factory environment and protected the roof and nearby equipment from corrosion. Second, when chemicals are used in processing, these floating balls help contain toxic vapours, improving air quality for workers.
Simple installation: Just pour the balls onto the tank surface—no extra systems needed.
Flexible coverage: Balls adjust to changing liquid levels during processing.
Long lifespan: Made from durable PP, they resist heat and mild chemicals.
Wide compatibility: We offer HDPE or PVDF balls if your process demands higher chemical resistance.
Over a decade later, Aluminium Bending – Croffles saving cash for factory remains a proven, energy-saving solution at ABS. The project shows how a straightforward approach can deliver multi-year returns and improve environmental performance.
