Metals & Foundries
In a foundry, the charge decision sets the cost of every heat. Getting it right by hand is difficult, and getting it right consistently across shifts is harder.
Charge optimization and process intelligence for metals production
Charge calculation is usually done in spreadsheets, one constraint at a time, with safety margin added to avoid breaching specification. That margin costs money on every melt, and the result varies with whoever is on shift.
MetalsCortex optimizes the whole problem at once, across all 18 elements and 50+ casting grades, and returns the lowest-cost mix that still meets specification. Our work around it covers configuration against your scrap inventory and pricing, plus the process intelligence that sits alongside it.
Common challenges
Manual charge calculation leaves margin
Optimizing elements sequentially means carrying extra safety margin to stay inside specification, on every heat.
Results vary by operator
Two experienced people will produce two different charges from the same inventory, so cost per melt is inconsistent.
Scrap inventory and pricing move
The optimal charge changes as scrap availability and alloy prices shift, faster than a spreadsheet gets revised.
Quality issues surface after the pour
Process problems that could have been predicted from earlier data are discovered once the heat is already committed.
What you gain
Lower raw-material cost on every melt
Reliable, repeatable specification compliance
Charge decisions standardized across shifts and operators
Quality issues anticipated rather than discovered
How we deliver it
The capabilities we use on metals & foundries projects.
Discuss a project with our engineers
Our engineering team is available to scope new projects, evaluate retrofits, and review system requirements.