Web-based Architecture
Browser-based user interfaces for production, metallurgy, quality and management.
Digitalization, Process Automation and AI-Supported Optimization for Foundries
foundry|365 is a foundry-specific application for charge calculation, cupola furnace, induction furnace and casting process automation, KPI/OEE reporting and AI-supported optimization based on
Features
Shared meltshop|365 platform capabilities.
foundry|365 uses the proven meltshop|365 platform architecture and extends it with foundry-specific process automation and metallurgical functionality.
KPI / OEE
Real-time dashboards for availability, productivity, quality and energy consumption.
Traceability
Complete traceability for heats, ladles, molds, materials and quality results.
ERP / LIMS Integration
Interfaces to ERP, laboratory systems, OPC UA and industrial automation systems.
Reporting
Production reports, quality reports, energy reports and management KPIs.
Hybrid Digital Twins
Combination of metallurgy, process models and AI-supported optimization.
System
Industrial IT architecture based on meltshop|365.
Web-based architecture for cloud, on-premises or hybrid industrial environments.
SQL Server / Oracle
Central production database for process tracking, traceability, quality management, reporting and KPI analytics.
Web Clients
Responsive browser-based clients without local desktop installation.
OPC UA Connectivity
Integration with PLCs, automation systems, scales, laboratory devices and sensors.
ProcessVars
Industrial middleware and application framework.
ProcessVars provides communication middleware, process variable management and industrial web application functionality used by meltshop|365 and foundry|365.
| OPC UA / OPC Classic | Industrial communication and PLC connectivity |
| Process Variables | Central variable management and historical tracking |
| C# Scripting | Automation logic and calculations |
| Alarm & Notifications | Email and popup notifications for process events |
| Web Applications | Browser-based industrial production applications |
Platform
One system for production, quality and continuous improvement.
foundry|365 is built for foundries that want to replace isolated tools, legacy visualization systems and manual Excel calculations with an integrated production platform.
Central data model
Orders, heats, batches, ladles, molds, materials, analyses, equipment and process events in one consistent database.
System integration
ERP, LIMS, PLC, OPC UA, scale systems, lab devices, energy meters and reporting platforms can be connected.
Web technology
Responsive browser-based user interfaces for production, metallurgy, quality, maintenance and management.
Process Coverage
From charging to casting — built around real foundry workflows.
The platform supports cupola, induction and duplex operations as well as downstream metallurgical treatment, pouring, quality documentation and traceability.
Raw Materials
Charge Calculation
Cupola / IF
Treatment
Pouring
Quality
AI-supported optimization
Hybrid digital twins for practical metallurgical decisions.
foundry|365 combines metallurgical know-how, physical models and machine learning. The goal is not AI as a black box, but decision support that operators and metallurgists can trust.
1
Collect and structure data
Production events, material data, analyses, temperatures, energy, delays and quality results.
2
Model the process route
Mass balance, yield, temperature loss, chemistry correction, treatment and pouring constraints.
3
Optimize decisions
Recommend material mix, alloy corrections, treatment windows and quality-relevant process actions.
Typical optimization targets
| Raw material cost | Scrap, returns, pig iron, alloys, inoculants and carburizers |
| Energy consumption | Melting energy, holding strategy, route losses and delays |
| Quality stability | Chemistry targets, Mg treatment, inoculation, nodularity and defect prevention |
| Traceability | Heat, batch, ladle, mold, material and lab result traceability |
| OEE and KPIs | Availability, productivity, quality, route performance and downtime causes |
Process automation
Automation for charge calculation, cupola, induction furnace and casting processes.
foundry|365 is not only a documentation system. The platform is designed to actively guide, automate and optimize foundry workflows — from raw material selection to pouring and ERP feedback.
Charge calculation automation
Automatic calculation of scrap, returns, alloys, inoculants and carburizers based on target chemistry, stock, yield, cost and production constraints.
Cupola furnace automation
Support for charge layers, coke rate, additions, tapping, temperature, chemistry, energy and operational deviations in cupola operation.
Induction furnace automation
Guidance for charging, melting, correction, holding, tapping and energy-related process decisions in induction furnace operation.
Casting process automation
Digital workflows for ladles, molds, pouring sequence, treatment windows, traceability, quality release and production feedback.
Solutions
Specialized solutions for modern foundry operations.
foundry|365 combines foundry MES functionality, process automation and AI-supported optimization for melting and casting operations.
Foundry MES
Production tracking, traceability, KPI/OEE reporting, quality documentation and real-time process transparency.
Charge Calculation Software
Automated charge optimization for scrap, pig iron, returns, alloys and inoculants with chemistry and cost constraints.
Cupola Furnace Automation
Digital support for cupola furnace operation including coke rate, tapping, temperature and chemistry control.
Induction Furnace Optimization
AI-supported melting optimization, holding strategy and energy efficiency for induction furnace operations.
Casting Process Automation
Digital workflows for treatment, pouring sequence, ladle handling, traceability and quality release.
Hybrid Digital Twins
Combination of metallurgical process models, AI and production data for robust process prediction and optimization.
Modules
Modular scope — from first quick wins to complete foundry digitalization.
Master Data
Materials, grades, target analyses, recipes, furnaces, ladles, molds, equipment and tolerances.
Charge Calculation
Cost-optimized batch calculation with chemistry, stock, yield, process and production constraints.
Melting Operations
Cupola, induction furnace and duplex route support with process tracking and operator guidance.
Treatment & Pouring
Inoculation, magnesium treatment, ladle handling, pouring documentation and thermal windows.
Quality & LIMS
Target analysis, sample management, lab integration, quality decisions and release workflows.
Reporting & KPI
OEE, energy, material consumption, deviations, quality costs and management dashboards.
Implementation
Start focused. Scale step by step.
foundry|365 can be introduced as a focused modernization project — for example charge calculation and reporting — and later extended into a complete foundry execution and optimization platform.
Cloud, on-premises or hybrid
Deployment options aligned with production IT, security and availability requirements.
Modernization of legacy systems
Replace old servers, PowerBuilder applications, isolated databases and manual Excel-based workflows.
Industrial IT experience
Based on GRIPS experience in production IT, process automation and metallurgy-driven optimization.
Next step
Discuss your foundry modernization potential in 30 minutes.
We review your process route, existing systems, pain points and the most realistic starting point for measurable savings.