SmartMelt
Your GPS for Aluminum Melting Optimization
Aluminum melting furnaces consume 700–1,400 kWh per tonne — up to 4× the theoretical minimum. SmartMelt closes this gap with a digital twin of your specific furnace, guiding operators through every step of the melting cycle — from charging to tapping — so each decision is backed by real-time data, not guesswork.
10%
Avg. Efficiency Improvement
0.5M€
Avg. Annual Savings per Furnace
100,000+
Hours in Service
24–110t
Furnace Capacity Range
How It Works
Data Acquisition
SmartMelt connects to your furnace controller and continuously collects operational data — temperatures, gas flows, door states, and material conditions — across furnaces from 24 to 110 tonnes. Installation takes just 2 months for the first furnace, and around 2 weeks for each subsequent one.
Digital Twin Simulation
The collected data feeds into a digital twin — a virtual replica of your specific furnace — that predicts the full cycle in seconds, tracking key indicators: melting rate (T/h), gas consumption (Nm³/T), overall efficiency (%), and door energy loss (MWh).
On-Line Comparison
Real furnace data is continuously compared against simulation results, identifying deviations and optimization opportunities as they happen — for example, detecting that a single unnecessary door opening can cause 5% energy loss.
Optimized Actions
SmartMelt recommends the next best action to the operator with clear, step-by-step guidance that requires under 1 hour of training. Simplified reporting makes results visible across the entire organization.
Key Features
Digital Twin Technology
A virtual replica of your specific furnace that combines efficient numerical calculations with real-time data acquisition, continuously tracking melting rate, gas consumption, overall efficiency, and energy losses throughout each cycle.
Data-Driven Optimization
Data from the furnace controller is analyzed and compared in real time to numerical simulation results, generating next-action recommendations — just as a GPS calculates the next turn based on current position and destination.
Energy Reduction
Close the gap between the 700–1,400 kWh/t typically consumed and the 325 kWh/t theoretical minimum by optimizing every phase of the melting cycle, reducing waste heat, and lowering operational costs by up to 0.5 M€ annually.
Cycle Time Minimization
SmartMelt identifies the optimal timing for each process step, reducing variability between operators and shifts. Consistent cycles mean predictable output and fewer delays.
Operator Assistance
Intuitive real-time guidance that requires under 1 hour of training. Operators receive clear next-action recommendations, while management gets simplified reports for cross-organizational visibility.
Field-Proven Reliability
With 100,000+ hours of service across EU and US facilities since 2019, SmartMelt is proven on furnaces from 24 to 110 tonnes. First furnace installation takes 2 months; each additional furnace just 2 weeks.
“Since February 2019, SmartMelt is running very smoothly at our Chippis plant. It is helping us to achieve safer loading practices, energy consumption reduction and overall more efficient melting cycles. We are eager to implement it in other casthouses of the group!”
Marc Bertherat
Casting Technical Assistance Manager, Constellium
100,000+ Hours Proving It Works
Facilities across EU and US are already saving up to 0.5 M€ per furnace per year. First furnace installation takes 2 months. Operators need under 1 hour of training. Results show from the first cycle.