Melt-iQ – Intelligent Charge Optimization for Foundries

Melt-iQ is a specialized software solution for cost-efficient charge optimization in modern foundries. The system supports melt supervisors in achieving metallurgical target analyses precisely, reproducibly, and economically.

Based on your inventory levels, defined analysis limits, and current raw material prices, Melt-iQ automatically calculates the optimal charge composition – taking into account melting losses, element pick-up, and the composition of the liquid heel.

Cost Reduction Through Data-Driven Charge Calculations

With Melt-iQ, material costs in melting operations can be significantly reduced. The intelligent charge calculation analyzes prices, chemical compositions, and available input materials in real time and delivers an economically optimized recipe.

Consideration of metallurgical parameters

• Target analysis with up to 25 elements

• Minimum and maximum limits per alloy element

• Melting losses and carbon pick-up

• Precise liquid heel calculation

• Dynamic price evaluation of input materials

This creates a transparent decision-making basis directly at the furnace.

What-If Analyses for Purchasing and Production

Melt-iQ enables simulations when prices change or new raw materials become available. Foundries can therefore evaluate the economic impact of alternative materials or market developments before they are used in production.

Strategic decision support

• Evaluation of new suppliers

• Analysis of price developments

• Comparison of multiple charge variants

• Immediate cost forecast

This transparency strengthens both technical and commercial departments.

Documentation, Traceability, and Process Reliability

All melts are automatically documented. Melt-iQ creates a chronological melting logbook and detailed statistics for engineering, quality assurance, and management.

Interfaces to crane scales and spectrometers enable direct data transfer without manual intermediate steps. Protocols can be exported and used for internal analyses or external audits.

Sustainability Through Precise Process Control

Optimized charge compositions reduce corrective melts, energy consumption, and CO₂ emissions. Melt-iQ helps foundries combine resource efficiency with economic performance.

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