ZIRCAR Refractory Composites

What ZIRCAR Refractory Composites does

ZIRCAR Refractory Composites, Inc. (ZRCI) is a US-based specialty manufacturer of advanced ceramic-ceramic composite materials serving high-temperature industrial applications. The company produces a comprehensive product line spanning rigid boards, cylinders, moldables, papers and felts, blankets, textiles, die-punched parts, rigidizers, coatings, and machined shapes — all engineered from alumina and silica-based matrices reinforced with ceramic fibers to deliver thermal insulation, structural strength, and electrical insulation across a 600°C to 2200°C temperature range. Its proprietary formulations include RS-100 (fiber-reinforced structural alumina), RS-99 (99%+ alumina for high-purity/reducing atmosphere use), RSLE-57 and RSLE-56 (low-expansion silica composites with exceptional thermal shock resistance), and the ZIRCAL calcium silicate board series.

ZRCI's primary customers are industrial buyers in foundry/metalworking, precision casting and investment casting, glass manufacturing (display, automotive, fiber optics), solid oxide fuel cell production, diamond segment sintering, and high-temperature electrical applications. Diamond segment manufacturers globally have widely adopted RSLE-57 due to its 10-20x lifespan advantage over alternative hot-press insulation. Revenue is generated through three channels: direct enterprise sales (quote-based pricing for industrial refractory products), a global distributor network, and a direct-to-consumer e-commerce storefront (Luminar Web Store) launched in 2024 for glass and bronze artists, which sells fixed-price mold mixes, moldable sheets, blankets, and coatings. The company operates from a single Florida, NY headquarters with 11-50 employees, was incorporated in the early 1970s following its origins at Union Carbide in the 1960s, and remains privately held with no disclosed institutional funding.

Name

ZIRCAR Refractory Composites

Legal name

ZIRCAR Refractory Composites, Inc.

Website

https://zrci.com

Company type

Private

Founded year

1970

Operating status

Operating

Headcount range

11–50 employees

Short description

ZIRCAR Refractory Composites manufactures advanced ceramic-ceramic composite materials (boards, cylinders, moldables, textiles) for high-temperature industrial applications from 600°C to 2200°C, serving foundries, precision casters, glass manufacturers, and diamond tool producers globally, plus a consumer line for glass artists.

Ownership category

akta.pro rank

Product category

Industrial Refractory Ceramic Composites

NAICS

Clay Building Material and Refractories Manufacturing (327120), Resin and Synthetic Rubber Manufacturing (32521)

SIC

Pottery & Related Products (3260), Plastic Materials, Synth Resins & Nonvulcan Elastomers (2821)

akta.pro primary industry

Specialty Polymers & Resins (Engineered Materials) (IMAEABAK)

akta.pro secondary industry

Thermoset & Reactive Resin Manufacturing (Epoxy, Polyester, Phenolic, Urethane systems) (IMANAAAC)

Keywords

• Ceramic composite materials
• Refractory insulation products
• High temperature boards
• Industrial furnace linings
• Molten metal handling

Headquarters

HQ city

Florida

HQ country

United States

HQ region

North America

Offices1 record

Markets served

GTM type

B2B and B2C

Offering type

Hardware or Manufacturing

Cost components

Supply Chain, Operations, Personnel, Technology or R&D, Marketing or Sales, Infrastructure

Revenue model

1. Refractory Composite Materials Sales: Primary revenue from selling advanced ceramic-ceramic composite materials including boards, cylinders, moldables, papers, blankets, textiles, and custom shapes. Products serve industrial applications (induction melting, forging, heat treating, investment casting, glass processing, hot pressing, high temperature electrical) and glass art markets. Revenue is generated through direct sales, e-commerce, and distributor channels.
2. Die Cut Parts and Custom Fabrication: Revenue from custom die-cut gaskets, spacers, and seals made from high temperature materials. Manufacturing to exact customer requirements with fast turnaround. Also includes custom boards and shapes fabricated to specification.
3. Consumer/Artist E-commerce Products: Direct e-commerce sales of Luminar Glass Products through the company's online store for hot glass artists. Includes mold mixes, moldable sheets, blankets, and coatings at various price points.

Pricing tiers

Go-to-market motion2 records

Distribution channels3 records

Marketing channels4 records

Core offering

ZIRCAR Refractory Composites, Inc. (ZRCI) manufactures and sells advanced ceramic-ceramic composite refractory materials in multiple physical forms (rigid boards, cylinders, moldables, papers, blankets, textiles, die-punched parts, rigidizers, coatings, and machined shapes) rated for high-temperature applications from 600°C to 2200°C. Products serve industrial customers in induction melting, forging, heat treating, investment casting, glass processing, hot pressing, and high-temperature electrical applications, plus a separate Luminar Glass Products line serving hot glass and bronze artists. Custom fabrication and die-cut parts are produced to customer specification.

Differentiator

Problem solved

Functional benefit

Brands

• Luminar Glass Products: Advanced materials designed specifically for artists working in hot glass and bronze, including casting, slumping, and fusing applications.

Products and services

• RS-100 Rigid Boards Fiber reinforced structural alumina composite boards used for high temperature, electrical, and structural insulation, and for transport of molten non-ferrous metals up to 1260°C. Available in standard sizes from 12x12 up to 48x48 inches. Serves industrial applications including induction melting, fuel cell packaging, heating coil supports, and steel melter insulation.
• RS-1200 Rigid Boards High strength alumina composite board for thermo-mechanical and electrical insulation in applications up to 1300°C (2372°F). Lower cost alternative to RS-100 with as-formed finish. For industrial users requiring high temperature insulation and machinable composite sheets.
• RS-200 Rigid Boards Refractory board used as casting spouts and tips for molten metal handling in foundry and casting operations.
• RS-99 Refractory Sheets High density fiber based ceramic with greater than 99% alumina purity for high vacuum, reducing atmospheres, and silica-intolerant applications up to 1650°C. Withstands 500+ hours continuous submersion in molten aluminum at 750°C. Available in three versions (moldable sheet, water-molded boards, pre-fired). For industrial users in vacuum, semiconductor, and specialty metal processing.
• RSLE-57 Low Expansion Silica Matrix Composite Low thermal expansion, high strength reinforced silica matrix composite for induction hot press applications and molten non-ferrous metal contact. Thermal expansion coefficient of 0.3 x 10-6 °C and thermal shock resistance up to 1200°C. Lasts 10-20 times longer than calcium silicate, mica, asbestos, or other hot press insulation. Industrial workhorse for diamond segment sintering.
• RSLE-56 Thermal Shock Resistant Moldable High silica fiber reinforced ceramic composite moldable with thermal expansion coefficient of 1.0 x 10-6 °C. Provides remarkable thermal shock resistance up to 1200°C (2192°F) and exceptional non-wetting properties with molten non-ferrous alloys. Used for trough liners, custom filter boxes for aluminum casting, and similar applications requiring thermal shock durability.
• RSLE-501 Cylinders Rigid refractory cylinders virtually thermal shock proof, designed for induction forging applications. Provides structural and thermal insulation for induction heating processes requiring rapid thermal cycling.
• RS-101 Cylinders Refractory cylinders made in many sizes up to 4 feet internal diameter and 5 feet tall. Used for furnace and fuel cell insulation applications. Combined with RS-100 and ZIRCAL-18 in high temperature fuel cell packages.
• RS-201 and RS-202 Cylinders Ceramic containers including closed end versions for solid oxide fuel cell applications. Rigid refractory cylinders designed for SOFC manufacturing and other high-temperature containment uses.
• ZIRCAL Calcium Silicate Boards Non-asbestos calcium silicate structural insulation boards combining high strength with excellent thermal insulating characteristics. Available in multiple grades (ZIRCAL-18, -45, -60, -95, -A) with temperature ratings from 650°C to 1100°C. ZIRCAL-18 offers lower thermal conductivity and cost than ceramic fiber and can be cemented to form large insulating structures. Available in 24"x48" and 36"x48" sizes in thicknesses from 1/2" to 4".
• Luminar Mold Mix 6 Refractory-molding compound for hot glass and bronze replication. Stable when heated, resists sticking, and can be reused for multiple cast or slumped parts. Tiered volume pricing from 1 quart bottles ($37.00) up to 5 gallon buckets (up to $364.00). For glass artists and bronze sculptors using lost wax casting and similar techniques.
• Luminar Mold Mix 7 Refractory-molding dry mix compound for hot glass and bronze replication. Single 1 gallon dry mix in bucket format at $60.00. Designed for durability, versatility, and creative flexibility in glass art and bronze casting.
• Luminar Moldable Sheets Moldable refractory sheets in 18x24 inch format at multiple thicknesses for hot glass and bronze art applications. Can be shaped and used for casting, slumping, and fusing. Stable when heated, resist sticking, and are reusable across multiple cast or slumped parts. For glass artists and craftspeople.
• Luminar Moldable Blanket Tough ceramic fiber reinforced insulation blanket in 24x36 inch size with 1/4" thickness, priced at $292.00. Designed for high temperature, high thermal shock applications in glass art and bronze studios.
• Luminar Glass Containment Molds Glass containment molds in 19L x 8W format at 1, 2, or 3 inch thicknesses, made from Luminar Fusing Sheet (ZRCI RS-100). Designed for hot glass containment and casting applications in art studios.
• Luminar Alumina Fusing Sheet Disc 9 3/4" diameter, 1/4" thick alumina fusing sheet disc, priced at $10.00. Reinforced structural alumina composite, long lasting alternative to ceramic kiln shelf for glass fusing and slumping in art studios.
• Custom Die-Cut Parts and Machined Shapes Custom die-cut gaskets, spacers, and seals made from high temperature composite materials to exact customer requirements with fast turnaround. Includes custom boards and shapes machined to specification. ZRCI materials can be machined to tight tolerances with standard tools.

Quantifiable outcome

• RSLE-57 lasts 10 to 20 times longer than calcium silicate, mica, asbestos or other hot press insulation in diamond segment sintering applications
• +2 more outcomes

Named customers3 records

Segments6 records

Ideal customer profiles4 records

Technology focussed Yes

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

Feature6 records

Scale indicators4 records

Recent moves6 records

Expansion highlights4 records

Broad incumbents

• Morgan Advanced Materials: Global leader in advanced ceramics and refractory components serving high-temperature industrial, electrical, and thermal-management applications. Highly comparable to ZRCI given overlap in alumina/silica-based composites, boards, cylinders, and high-temperature insulation products.
• HarbisonWalker International (HWI): One of the largest North American refractory manufacturers, supplying monolithics, bricks, and preformed shapes to foundries, steel, glass, and cement customers. Comparable to ZRCI as a high-temperature refractory supplier serving overlapping industrial end markets.
• Alkegen (formerly Unifrax): Global manufacturer of high-temperature insulation fibers, boards, and microporous products for industrial, EV battery, and filtration applications. Directly comparable to ZRCI's ceramic-fiber-reinforced boards, papers, blankets, and textiles used in furnaces and high-temperature processing.
• Saint-Gobain: Diversified global materials company with a significant refractory and high-performance ceramics business (including Carborundum). Comparable to ZRCI in alumina and silica-based refractory components for industrial high-temperature applications.
• Corning Incorporated: Global advanced materials company with technical ceramics and high-temperature glass-ceramic product lines serving industrial and emissions-control applications. Adjacent comparable to ZRCI's specialty ceramic composite materials and high-temperature industrial focus.

Direct peers

• Pyrotek: Specialty manufacturer of high-temperature materials, non-wetting refractories, and molten-metal handling systems for aluminum, zinc, and glass industries. Highly comparable to ZRCI's RS-99/RSLE-56 non-wetting composites used in non-ferrous metal processing.
• BNZ Materials: Manufacturer of high-temperature calcium silicate and insulating firebrick products used in industrial furnace and process equipment. Direct comparable to ZRCI's ZIRCAL calcium silicate boards and refractory composite insulation products.
• Rath USA: Producer of high-performance refractory products including bricks, castables, and ceramic fiber modules for industrial furnaces. Comparable to ZRCI's range of high-temperature boards, cylinders, and textile insulation for industrial thermal management.
• CoorsTek: Specialty technical ceramics manufacturer producing alumina and other advanced ceramic components for industrial, semiconductor, and aerospace markets. Comparable to ZRCI as a maker of high-purity alumina and engineered ceramic composite components.
• Skamol: Danish manufacturer of high-temperature calcium silicate and microporous insulation boards for industrial, building, and process equipment. Direct comparable to ZRCI's ZIRCAL calcium silicate boards and other high-temperature board products for furnace insulation.

Market position

Strengths5 records

Weaknesses5 records

Competitive moat4 records

Key risks7 records

Key highlights7 records

Customer concentration

• LinkedInlinkedin.com/company/zircar-refractory-composites-inc-

Revenue estimate

Valuation estimate

Number of profiles

Funding overview

Funding rounds

Investors

Funding detail is available on the Subscription and Enterprise plan.Contact sales →

M&A

Investments

M&A and investment is available on the Subscription and Enterprise plan.Contact sales →

Frequently asked questions about ZIRCAR Refractory Composites