Smart Foundry Solution: 22% Energy Savings, 28% Less Material Use
Challenges
ICP DAS USA Smart Retrofit Solution
ICP DAS USA’s Smart Retrofit Solution addresses these challenges by collecting real-time production and energy data, centralizing monitoring, and providing actionable insights to optimize operations. This data-driven approach improves process consistency, reduces energy consumption, and enables informed decision-making without disrupting production.
1. Raw Material and Casting Treatment Area: Intelligent Weight Monitoring
The ICP DAS USA I-7188XBD controller reads weight data from electronic scales via RS-232 and works with the ICP DAS USA X107 I/O expansion module to monitor scale button inputs. This automated solution streamlines data collection and improved the accuracy of raw material and finished product tracking.
Operators select the appropriate raw material using dedicated buttons on the weighing station. The ICP DAS USA I-7188XBD controller automatically records the weight, timestamp, and material ID, then transmits the data through the ICP DAS USA RFU-433 wireless modem.
To support a proprietary scale protocol, ICP DAS USA developed custom firmware that converts measurement data to Modbus RTU, enabling seamless integration with production monitoring systems.
2. Melting Area: Intelligent Energy Monitoring
To reduce energy waste during the melting process, ICP DAS USA’s solution uses a PM-3133-RCT2000P smart power meter and Rogowski coil sensor to monitor furnace power consumption in real time. This enables accurate energy tracking, helps prevent overheating, and provides the data needed to optimize furnace operation and improve efficiency.
The flexible Rogowski coil is designed for high-current applications up to 2000 A, making it ideal for induction furnace monitoring and installation around large busbars in limited spaces.
The ICP DAS USA VPD-173N-64 HMI centralizes data from the power meter, environmental data logger, and wireless communication network, providing operators with real-time visibility into key production metrics.
The display includes material weights, melting status, energy consumption, trend charts, temperature-holding reminders, and environmental conditions, enabling efficient monitoring and better operational control from a single interface.
Because the induction furnace operates as a standalone system without built-in communication capabilities, operators manually configure process parameters through the ICP DAS USA VPD-173N-64 HMI. Parameters such as steel weight, gain, and offset values are used to adjust the melting curve and calculate the optimal temperature-holding period.
When the melting process reaches the predefined stage, the HMI automatically activates a temperature-holding reminder. This alerts operators to switch the furnace from heating mode to holding mode, helping prevent overheating and unnecessary energy consumption. By providing timely guidance, the system improves process consistency and supports energy-saving operations.
Office Area: Centralized Data Management and Visualization
The central control computer receives production and energy data from the melting area through the ICP DAS USA RFU-433 Wireless Modem. Using AVEVA Edge software, plant personnel can visualize, analyze, and manage production, energy usage, and carbon emissions from a centralized platform.
To enhance visibility, an ICP DAS USA iKAN-124-IP65 Industrial LED Display is connected to the control system via Ethernet. The display presents key operational metrics in real time, including raw material consumption, energy usage, carbon emissions, and production output. This gives operators and managers instant access to critical performance data, supporting informed decision-making and continuous process improvement.
Real-Time Monitoring and Carbon Emissions Analysis
The system provides real-time visibility into energy consumption, environmental conditions, raw material usage, and production cycle data. Built-in alerts help managers quickly detect and resolve operational issues, improving process reliability.
The SCADA platform centralizes production, yield, and carbon emissions data, offering intuitive dashboards and reports that support informed decision-making and continuous sustainability improvements.
Benefits
Wireless Communication Reduces Installation Complexity
Traditional foundry environments can make cable installation difficult and costly. To address this challenge, the solution uses ICP DAS USA RFU-433 Wireless Modems, which transmit data over the 433 MHz ISM frequency band. This wireless architecture minimizes cabling requirements, lowers installation costs, and simplifies system deployment while maintaining reliable communication between production areas and the control office.
Improved Efficiency Through Automated Data Collection
The automated data acquisition system eliminates the need for manual recordkeeping, reducing labor requirements and minimizing the risk of transcription errors. Production and energy data are automatically collected, stored, and visualized, making it easier for personnel to access information, perform analysis, and identify opportunities for process improvement.
22% Reduction in Energy Consumption and Carbon Emissions
The solution continuously collects data on raw material usage, energy consumption, ambient conditions, and melting duration. By analyzing the relationship between these variables, the system helps identify the optimal energy requirements for each melting cycle.
Using factors such as material weight, ambient temperature, and processing time, the platform generates recommended energy targets and operating guidelines that support more precise furnace control. This data-driven approach reduced the molten iron tapping temperature from 1509°C to 1444°C, significantly lowering energy use and associated carbon emissions.
As a result, the foundry achieved a 22% reduction in annual electricity consumption, delivering approximately $30,000 in annual energy cost savings while supporting its sustainability goals.
28% Reduction in Raw Material Waste
The solution includes a comprehensive raw material weight management system that helps operators measure and feed materials more accurately throughout the production process. By improving material control and reducing overfeeding, the foundry achieved a 28% reduction in casting material waste, lowering both production costs and environmental impact.
Increased Production Efficiency
By leveraging real-time production and energy data, the system enables a more precise furnace heating strategy. Optimized heating parameters reduce unnecessary processing time, shorten melting cycles, and improve overall production throughput, helping the foundry operate more efficiently.
Comprehensive Carbon Emissions Tracking
Some materials, including hardeners, furan resins, and coating agents, still require manual weighing during production. To ensure complete emissions accounting, the SCADA platform provides dedicated input fields for material quantities and associated CO₂ emission factors. This allows operators to accurately calculate carbon emissions from both automated and manually tracked processes, delivering a more complete view of the facility’s environmental performance.
Conclusion
ICP DAS USA’s customized monitoring and data acquisition solution helps foundries improve efficiency, reduce energy and material waste, and accelerate their digital transformation journey.
By combining precise process control with centralized SCADA-based production and carbon emissions management, the solution supports smarter operations, lower operating costs, enhanced sustainability reporting, and more effective carbon footprint management.
