FAQ
Alloy charge calculation is the process of determining and optimizing the composition of metal alloys in foundries. It is crucial to ensure that the final products meet the desired physical and chemical properties. The cost of raw materials can be highly volatile. Our software takes these fluctuations into account and optimizes the alloying process according to precise customer rules, ensuring low costs. Metallurgical boundaries are closely monitored, and any deviations are promptly addressed.
Our software enhances the accuracy and efficiency of alloy charge calculations, reduces material costs, minimizes errors, and increases productivity in the melting operation. Melt-IQ stores all metallurgical parameters and continuously seeks the most cost-effective solution. The software reduces the need for costly and time-consuming recharges, thereby improving productivity in the melting department, which is often a bottleneck in the foundry. Melt-IQ also reduces emissions and energy consumption in the melting process.
While Excel spreadsheets are a useful tool in many areas, they quickly reach their limits when it comes to complex charge optimization. Melt-iQ, on the other hand, offers a specialized software solution specifically developed to meet the needs of the foundry industry:
- Automated Optimization: Melt-iQ uses advanced algorithms that calculate thousands of possible combinations within seconds and immediately suggest the optimal composition. In Excel, this would require manual trial and error, which is very time-consuming.
- Cost Savings: With Melt-iQ, it is proven that 5-15% of the costs for charge materials can be saved. Manual calculation in Excel often does not achieve the same savings, as many factors can be overlooked.
- Error Minimization: The software minimizes human errors that can easily occur during data entry and calculation in Excel. Melt-iQ ensures that calculations are accurate and precise.
- Network Capability: Melt-iQ connects various departments and enables real-time data exchange between production, purchasing, and controlling. In contrast, Excel files need to be manually updated and shared, which can lead to inconsistencies.
- Ease of Use: Unlike complex Excel spreadsheets, users do not need in-depth mathematical knowledge to operate Melt-iQ. The software is intuitive and user-friendly, allowing even foundry employees without programming or Excel experience to perform optimizations effectively.
The software includes features such as alloy calculation, material database, customization for specific requirements (e.g., burn-off, charge addition, material surcharge calculation, what-if scenarios for pricing or analysis), and reporting tools for purchasing, sales, and controlling. Melt-IQ makes collected data available for Microsoft Excel, Word, or an ERP system.
Yes, our software is designed to run on Microsoft operating systems. Melt-IQ can be customized to integrate with your existing ERP system. Interfaces to spectrometers are programmed as needed.
The installation and configuration process is user-friendly and supported by detailed instructions. Melt-IQ can be installed on a single computer or across a network. Additionally, a dongle from WIBU-Key is required. We also offer support throughout the entire installation process.
The software requires a modern PC running Windows 10 or higher, with at least 4 GB of RAM and 500 MB of free hard disk space. An internet connection is recommended for updates and support.
Yes, we offer a free trial version so you can test the software before making a purchase.
We provide comprehensive support via phone, email, and live chat. Additionally, we offer training videos, user manuals, and webinars.
Your data remains locally stored on the customer’s computer.
The software is regularly updated with new features and improvements based on customer feedback and technological advancements.
Yes, we offer tailored solutions to adapt the software to the specific requirements of your foundry.
The software supports a wide range of materials and alloys commonly used in the foundry industry, including iron and steel alloys as well as highly alloyed grades. Melt-IQ can manage up to 15 batch furnaces. Cupolas are not supported, as charging in these is discontinuous.
Our software utilizes precise algorithms, such as linear optimization, to ensure highly accurate calculations.
The software supports multiple languages, including German, English, French, Spanish, and Turkish.
The software is offered on a subscription basis. Costs vary depending on the type of license and additional services. For a personalized quote, please contact our sales department.