Refcoat foundry additives — molten metal pour, engineered castings, and sand grains

Foundry additives, engineered with nanotechnology

Refcoat designs nano-scale chemistry for green sand iron foundries — replacing coal dust, optimising bentonite, and removing the refractory coating step. The only company globally building nanotechnology additives for sand casting. Verified in commercial trials from Sweden to South India.

50% Coal dust reduction
Rajmane Industries
1.1% → 0.58% Bentonite consumption
Rajmane Industries
67.8% CO emission reduction
Swedish iron foundry, verified
EPD Independently verified
Nanokarb

Why nano-scale chemistry changes foundry economics

Strip the assumption that foundry additives are bulk commodity inputs. At nano-scale, the same gram of material exposes orders of magnitude more reactive surface area than a milled particle — which means lower addition rates, higher specificity, and outcomes that micron-scale chemistry cannot reach. Refcoat is the only company globally engineering this approach for green sand foundries. Every product on this page is built from that single principle, validated in commercial trials with measurable, third-party-verified results. The economic translation is direct: less material consumed per casting tonne, lower emissions per tonne, lower CBAM exposure per export tonne, and a smaller compliance burden every quarter.

The Refcoat product portfolio

Nano carbon additive

Nanokarb

Replaces coal dust with ceramic-nanoparticle chemistry

Engineered ceramic nanoparticles act at the mould–metal interface, delivering the surface-finish and casting-quality outcomes that coal dust is added to provide — without combustion. Independently verified to cut coal dust consumption by 50% in commercial trials. Compatible with existing green sand systems at standard addition rates. EPD published. Patent pending. Designed as a fundamentally different approach to mould-surface chemistry, not a coal-dust analogue.

50% coal dust ↓ 67.8% CO ↓ (verified trial) EPD verified
  • Drop-in replacement
  • Lower CBAM exposure
  • Standard addition rate
  • Independent EPD
View Nanokarb → Nanokarb vs traditional coal dust →
Bentonite optimisation

MouldMax

Cut bentonite consumption by 10% — minimum

MouldMax improves active-clay efficiency in the green sand system, raising bentonite retention and lowering replacement frequency. At Rajmane Industries, 6 months of MouldMax (paired with Nanokarb) brought bentonite consumption from 1.1% of total sand mass down to 0.58%, while green compression strength and permeability stayed within spec. Designed for continuous green sand systems running iron and steel.

Min 10% bentonite ↓ 1.1% → 0.58% (Rajmane) GCS maintained
  • Maintains permeability
  • Continuous-system compatible
  • No new equipment
  • Pairs with Nanokarb
View MouldMax → MouldMax for your foundry →
Coating-free refractory

Nanocore

Eliminate the refractory coating step entirely

Nanocore is a refractory raw-material technology that produces a stable mould surface without a separately applied coating. Removes the coating-application step entirely, eliminating the associated VOC emissions and process time. Available in two formats: a refractory coating replacement, and a refractory raw material for cores and moulds. Standard cure cycle. Surface finish parity with traditionally coated cores.

100% coating elimination No VOC drying step Standard cure
  • No coating step
  • Lower VOC emissions
  • Surface finish parity
  • Two product formats
View Nanocore → As refractory coating → As raw material →

Built for the post-CBAM foundry

Every Refcoat product on this page reduces a measurable input — coal dust, bentonite, refractory coating — that carries CO2, CO, and VOC emissions per tonne of casting. In a verified Swedish iron foundry trial, Nanokarb cut CO emissions by 67.8% and overall carbon by 52.7%. As CBAM enters its definitive period, that delta translates directly into reduced certificate liability per export tonne. Foundries already exporting to the EU are quantifying their embedded-emissions exposure now and finding it grows with every quarter of inaction. CBAM-specific compliance and reporting workflow is supported separately by C-Minus-B, Refcoat's sister organisation, which handles the regulatory and submission layer.

67.8% CO ↓  ·  52.7% carbon ↓  ·  EPD verified

Start with a foundry assessment

Foundries running on traditional coal dust lose 50% of that material to combustion, carry measurable bentonite over-consumption, and face growing CBAM exposure on every export tonne. A 90-minute Refcoat foundry assessment maps where your foundry sits today — sand chemistry, additive efficiency, emissions footprint — and identifies which Refcoat product moves the curve fastest.

Book a foundry assessment See verified case studies →