How Nanokarb Works

In conventional green sand moulding, coal dust and similar carbon additives combust when molten metal enters the mould. The foundry industry has long believed this combustion produces a protective layer between the metal and the sand — both the conventional explanations for that belief (the "lustrous carbon" hypothesis and the "gas cushion" hypothesis) struggle to hold up under first-principles scrutiny. What the combustion actually does is start a chain reaction inside the sand matrix: temperatures spike in the backing sand, water evaporates prematurely, bentonite loses its bond strength, and the sand system degrades with every cycle.

Nanokarb works differently. Its ceramic nanoparticles form a protective interface at the mould-metal boundary — without combustion. With 0% volatile matter at 400°C and less than 10% at 925°C, Nanokarb does not burn inside the mould. There is no secondary heat source. There is no chain reaction. The backing sand stays cooler, water is preserved, and bentonite performs at its full potential. The same LOI test the foundry already runs controls dosage; minimum effective dosage is 0.075%.

This is also why 1 kg of Nanokarb replaces 2 kg of conventional coal dust. While both have similar LOI values, the difference is in how they perform. Coal dust relies on combustion — a process that wastes energy and degrades your sand. Nanokarb's ceramic nanoparticles create the protective interface at the mould-metal boundary through engineered surface properties, not through burning. The result is better protection with less material, and none of the collateral damage.

Proven Results Across India and the EU

Nanokarb is commercially used in foundries across India and the European Union. Results are consistent across foundries of varying melting capacity, across moulding line types, and across metal grades: