📍 Smarttherm Power Technologies • India ✉️ info@smarttherm.in 🌐 www.smarttherm.in
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âš¡ Industry Leader in Solid-State Induction Heating

Precision Induction Heating & Melting Systems

Engineered for optimum thermal efficiency, near-unity power factor (0.98–0.99), and rugged manufacturing operations. From high-throughput forging billet heaters to precision CNC hardening and coreless melting furnaces.

Explore Machine Lineup Calculate Energy Savings

30+

Years of Design & Manufacturing

550+

Industrial Plants Installed

0.99

Optimum Input Power Factor

30–40%

Productivity Boost vs Fuel Furnaces

Automated IGBT Induction Billet Heater with Glowing Steel Billet

Forge Master I-Series (IGBT)

Digital Control • Automated Conveyor

98.6%
Engineering Excellence

Over Three Decades of Induction Innovation

Promoted by veteran engineering professionals with more than 30 years of specialization in industrial thermal power electronics, Smarttherm Corporations delivers world-class custom heating and melting solutions designed to lower total ownership costs.

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Advanced IGBT Solid-State Tech

Equipped with modern IGBT-type inverters and proprietary digital control boards for maximum conversion efficiency, immediate response, and lowest harmonic distortion on factory grids.

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Built for Heavy 24/7 Operations

Robust mechanical architecture with bronze pump DWRS (De-mineralized Water Recirculation Systems), plate-type heat exchangers, and integrated multi-point interlock safety protection.

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Turnkey Automation & Robotics

Seamless integration with Allen-Bradley PLC & HMI interfaces, dual-color infrared laser pyrometers, automated pusher/conveyor billet feeders, and pneumatic reject gates.

Engineered Systems

Comprehensive Machine Portfolio

Explore our heavy-duty product lineup engineered for forging shops, foundries, tube mills, and precision heat-treating plants.

IGBT Solid State Inverter

Forge Master I-Series Billet Heater

High-frequency, fast-response induction billet heating system engineered specifically for precision forging and fastener applications. Provides instantaneous heating with minimal scale formation.

Power Rating Billet Size Range Operating Frequency Inverter Architecture
50 kW – 250 kW 7 mm – 24 mm 30 kHz Fast-Switching IGBT
50 kW – 350 kW 20 mm – 40 mm 10 kHz Resonant IGBT
50 kW – 350 kW 40 mm – 65 mm 3 kHz High-Current IGBT
  • Dimensions & Weight: Ultra-compact footprint 2.5m × 1.0m × 1.4m (~1.55 Tons).
  • Cooling & DWRS: Heavy-duty bronze pump with stainless plate heat exchanger.
  • Automation: Allen-Bradley PLC & HMI with dual-color laser pyrometer sorting.
  • Optional Feeders: Magazine pushers, vibratory bowls, and walking-beam conveyors.
Request I-Series Specs
I-Series Induction Billet Heater with Red Hot Steel Billet

Forge Master I-Series In Action

Continuous uniform billet heating with 0.8% minimal scale loss

Heavy Duty Industrial Forging

Forge Master T-Series High-Capacity Heater

Built for high-volume automotive forging presses and large bar-end heating operations. Capable of throughputs up to thousands of kilograms per hour with superior thermal penetration.

Power Rating Bar/Billet Diameters Frequency Inverter Architecture
100 kW – 1000 kW 40 mm – 65 mm 6 kHz IGBT / Hybrid Thyristor
100 kW – 1000 kW 50 mm – 70 mm 3 kHz Medium Frequency Solid State
100 kW – 1500 kW 60 mm – 120 mm 1 kHz Deep Penetration Thyristor/IGBT
100 kW – 2000 kW 120 mm – 200 mm 0.5 kHz High-Tonnage Heavy Inverter
  • Bar End & Full Billet: Dual-mode capability for bar upsetting and press forging.
  • Digital Multi-Zone Heating: Independent power control across preheating and soaking zones.
  • Hydraulic Pinch Roll: Continuous motorized feed with optical temperature verification.
Request T-Series Quotation
T-Series Heavy Induction Bar Heater

High-Tonnage T-Series System

Engineered for forging presses up to 4000 tons capacity

CNC Case Hardening & Quenching

Precision Vertical & Horizontal Induction Scanners

Automated surface hardening equipment for automotive drive shafts, gears, axle spindles, and machine ways. Delivers exact metallurgical case depths without component distortion.

Configuration Max Component Length Power Range Motion Control
Single Spindle Vertical Up to 1500 mm 50 kW – 250 kW Multi-Axis CNC Servos
Dual Spindle Vertical Up to 2000 mm 100 kW – 400 kW High Speed Production CNC
Rotary Table / Horizontal Custom Gear Diameters 50 kW – 350 kW Precision Indexing Table
  • Localized Case Depth: 1.5mm to 8.0mm precision controlled hardness pattern.
  • Integrated Quench Station: Polymer or water-glycol quench ring with flow monitoring.
  • Recipe Management: Store 100+ CNC hardening profiles for rapid changeovers.
Consult On Hardening Solution
Vertical CNC Induction Hardening Machine with Active Water Quench

CNC Vertical Induction Scanner

Localized heat band with synchronized high-pressure quench

Medium Frequency Coreless Furnace

IGBT Induction Melting Furnaces

High-yield melting systems for iron, steel alloys, brass, copper, and precious metals. Offers rapid melt cycles, natural electromagnetic stirring for uniform alloy composition, and zero point-of-melt carbon emissions.

Power Source Crucible Capacity Operating Frequency Melt Time (Average)
150 kW – 350 kW 100 kg – 300 kg 1000 Hz – 2500 Hz 35 – 45 minutes
350 kW – 750 kW 500 kg – 1000 kg (1 Ton) 500 Hz – 1000 Hz 40 – 55 minutes
750 kW – 1500 kW 1000 kg – 1500 kg (1.5 Ton) 300 Hz – 600 Hz 50 – 65 minutes
  • Hydraulic Tilting: Smooth hydraulic cylinders with proportional joystick tilting control.
  • Energy Efficiency: ~520 to 580 kWh per ton of melted steel alloy.
  • Environmental Compliance: Eliminates toxic foundry smoke, SOx, and greenhouse emissions.
Inquire About Melting Systems
Hydraulic Induction Melting Furnace Pouring Molten Metal

1.5 Ton Coreless Melting Furnace

Precision hydraulic pouring with electromagnetic melt stirring

Solid State Current-Fed Inverter (CFI)

High-Frequency Induction Tube & Pipe Welder

Solid-state high-frequency induction and contact seam welders for tube mills. Engineered for carbon steel, stainless steel, aluminum, brass, copper, and advanced HSLA structural tubing.

Characteristic Technical Specification
Power Range Up to 1000 kW Solid State (MOSFET / IGBT)
Stabilized Frequency 150 kHz – 400 kHz (±1% automated tracking)
Electrical Efficiency > 85% System Overall Efficiency
Power Factor 0.92 at all line speeds
Welding Method Induction Coil & Dual Contact Welding
  • AutoMatchâ„¢ Impedance: Automatically locks matching frequency as tube wall gauges change.
  • Zero Spatter Edge Fusion: Clean forge weld seam with minimal internal weld bead.
  • Speed-Power Synchronization: Dynamic power adjustment proportional to mill run speed.
Request Welder Quotation
High Frequency Induction Seam Pipe Welder

Continuous Mill Seam Welder

Precision high-frequency apex fusion with real-time temperature tracking

Economic Benchmark

Induction Heating vs Fuel-Fired Furnaces

See why over 500+ manufacturing plants have replaced conventional oil-fired and gas-fired billet heating furnaces with Smarttherm solid-state induction systems.

Evaluation Parameter Smarttherm Induction Billet Heater Oil-Fired Furnace Gas-Fired Furnace
Operating Running Cost ₹ 3.00 / kg ₹ 5.60 / kg ₹ 5.00 / kg
Scale Loss (Raw Steel Loss) 0.8% (Huge Raw Material Saving) 4.5% (High burning loss) 3.4% (Substantial scale)
Shopfloor Productivity +30% to +40% Boost (Automation) Low (Heavy manual handling) Operator dependent
Billet Temperature Uniformity Exact ±25°C Cross-Section Erratic ±75°C variation Fluctuating ±75°C
Cold Startup Time Instantaneous (1 to 2 Minutes) At least 60 to 90 Minutes At least 60 Minutes
Tooling & Forging Die Life Significantly Increased (No abrasive scale) Rapid die wear High die wear
Environmental & Carbon Footprint Clean, Eco-Friendly, Zero Exhaust Extremely polluting exhaust High emissions & greenhouse gas

Interactive Savings Calculator

Slide your plant's estimated daily billet heating capacity to see immediate raw steel and energy savings.

* Calculations modeled on 25 operational shifts/month, market steel rate of ₹60/kg, and 3.4% scale reduction vs fossil combustion.

Monthly Steel Saved

12,750 kg

Monthly Net Savings

₹ 16,27,500

Projected Annual ROI

₹ 1.95 Cr

Monthly COâ‚‚ Offset

68 Tons

Client Endorsements

Trusted by Leading Forging & Foundry Plants

Real feedback from manufacturing directors who rely on Smarttherm induction equipment daily.

"I am thoroughly impressed with our induction billet heaters (250 kW / 3 kHz and 450 kW) installed in 2014 and 2017. Their after-sales service and engineering support have been prompt and reliable. I recommend Smarttherm without hesitation."
TK

Forging Division Head

Heavy Forging Plant, India

"Our company placed repeat orders for 150 kW / 10 kHz (2 units), 200 kW, and 350 kW / 1 kHz billet heaters across 2013, 2014, and 2018. The machine flexibility, uptime, and efficiency are exceptional. Thank you for the proactive support."
VY

Operations Director

Automotive Components Mfg.

"We ordered a 400 kW / 1 kHz induction heater in 2014. The equipment delivered exactly to technical commitments: compact footprint, minimal floor space requirement, and superior energy efficiency. Highly satisfied with performance."
KK

Technical General Manager

Precision Engineering Works

Get in Touch

Request a Technical Consultation or Quote

Share your component dimensions, material grade, and required production tonnage per hour. Our design engineering team will provide a tailored machine layout and electrical proposal.

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Sales & Engineering Inquiries

info@smarttherm.in / sales@smarttherm.in

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Official Online Portal

www.smarttherm.in

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Equipment Specification Form

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