Live on Your Network · Works Offline

Every melt,
calculated.
Not guessed.

Intelomelt replaces spreadsheets and gut-feel with a precision charge calculator, LP-optimised trim correction, and an AI metallurgical assistant — built for induction furnace foundries.

Iron & Steel All Major Grades Works Offline LP Solver
Talk to Us

No obligation · Free 30-day trial · Setup in under 1 hour

GS42CrMo4V
H001 · Furnace 2 · 4,850 kg
Live Chemistry
—
Predicted Yield
—
Charge Cost
Chemistry within aim — heat ready to tap
Data stays on your network
Runs offline — no internet needed
Live in under 1 hour
Live across Asia Pacific and the Middle East

Trusted in production by

Secondary Aluminium Ingot Manufacturer
Middle East
Intelomelt Alu ADC12 · LM6 · LM24 Live in Production

Using Intelomelt Alu for HF Trim LP correction, charge planning across ADC12 and LM6 grades, recovery learning, degassing tracking, and automated batch report generation.

Iron and Steel Casting Foundry
Asia Pacific
Intelomelt Iron Induction Furnace Live in Production

Running Intelomelt for charge optimisation, ERP integration, heat logging, and the production dashboard across iron and steel casting grades in active production.

Active in Asia Pacific and the Middle East · More foundries onboarding

The Problem

Your foundry is losing money
on every heat it guesses.

Manual charge planning, conservative alloy over-additions, and spectro results entered by hand add up to thousands per shift in avoidable waste — whether you cast iron, steel, or aluminium.

Without Intelomelt
Manual spreadsheets with copy-paste errors between shifts
Add extra alloy "just to be safe" — over-additions cost AUD 20–70 per heat
No traceability — who charged what, when, and why
Trim corrections done by memory and gut feel
Spectrometer readings typed by hand — one wrong digit fails the heat
Melt loss factors set years ago, never updated — yield predictions wrong
Reports take 20+ minutes to prepare per shift
With Intelomelt
Charge chemistry predicted in real time as you build the mix
LP solver finds the minimum alloy addition — not the safe one
Every heat logged with full audit trail — charge, chemistry, operator, temps
Trim corrections calculated to the kilogram from spectro results
Spectro import with validation eliminates manual entry errors
Self-learning recovery: system measures actual yield and auto-corrects after 20 heats
Print-ready branded melt report in one click
Intelomelt — Iron & Steel

Everything your metallurgist
needs, in one system.

Built specifically for induction furnace foundries casting iron and steel. Not a generic MES — a precision tool for the melt shop floor.

Iron & Steel
Charge Calculator
Build multi-material charges against any grade. Predicted chemistry updates live as you adjust weights. Element bars show green within aim, red outside spec — before you light the furnace.
Iron & Steel
LP Trim Correction
Enter your spectro result. The LP solver calculates the minimum-weight alloy additions to bring every element within grade limits. Exact kilograms — not a conservative estimate. Solves in under 2 seconds.
Iron & Steel
Charge Optimiser
Find the cheapest scrap and returns combination that hits grade chemistry. LP-optimised — mathematically the cheapest valid blend from your available stock.
Iron & Steel
Hardenability (DI)
Grossmann Ideal Diameter and full Jominy end-quench curve calculated from actual spectro chemistry per ASTM A255. Know hardenability before the furnace is tapped.
Iron & Steel
AI Metallurgist
Ask metallurgical questions in plain English. Context-aware answers using your actual heat data, grade specs, and material library. Available on every shift. Runs fully offline.
Iron & Steel
Self-Learning Recovery
Tracks actual vs. predicted melt loss for every material over every heat. After 20 heats, EMA smoothing auto-corrects recovery factors per material.
Unique Feature
Iron & Steel
Heat Log
Every heat saved automatically with full traceability — charge mix, half-sample spectro, final spectro, temperatures, alloy additions, operator, furnace, tap weight.
Iron & Steel
Print Reports
One-click branded melt reports — chemistry table, ladle additions, per-tap splits, deox quantities, operator sign-off. Print in under 10 seconds.
Iron & Steel
Production Dashboard
Live KPIs — heats per day, yield trend, alloy consumption, chemistry trends, operator performance, DI distribution. Period filter and cost analysis built in.
Iron & Steel
Spectro Link
Direct import of spectrometer readings from Bruker, Metal Power, and other OES systems. Spectro results populate the trim correction screen automatically.
Coming Q4 2026
Intelomelt Alu — Aluminium Edition

Aluminium melt intelligence.
Purpose-built for Al foundries.

Aluminium is not iron. Intelomelt Alu is built specifically for the Al-Si-Cu-Mg-Zn alloy system — with degassing tracking, grain refiner dosing, modifier fade timers, and hydrogen porosity monitoring that iron-focused tools don't have.

Intelomelt Alu
Alu Charge Calculator
Calculate charges for ADC12, LM6, LM24, LM25, A356, A380 and more. Tracks Al, Si, Cu, Mg, Zn, Fe, Mn, Ti with per-material recovery factors. Fe contamination alert when approaching grade limits.
Intelomelt Alu
HF Trim LP Correction
Enter half-furnace spectrometer result. LP solver calculates minimum AlSi20, AlCu50, AlMg10 additions to hit grade aim chemistry. Mg volatility correction (×1.15) applied automatically.
Intelomelt Alu
Degassing Tracker
Log N₂/Ar flow rate, rotary degassing time, and RPT density index per cast. Alert fires when density index exceeds 2% (porosity risk). Trend chart shows RPT results over time by grade.
Alu-Specific
Intelomelt Alu
Grain Refiner Calculator
Input charge weight and grade — get precise AlTiB rod length (metres) or tablet quantity. Calculates Ti and B ppm delivered to the melt. Accounts for fade time and addition method.
Alu-Specific
Intelomelt Alu
Modifier Fade Timer
Track Sr (strontium) modifier addition time and dosage. Live fade calculator shows remaining Sr effectiveness in the melt. Critical alert when modification falls below threshold before casting.
Alu-Specific
Intelomelt Alu
AI Metallurgist — Alu
Context-aware for aluminium: asks about your density index, Mg burn-off, Fe contamination source, grain refiner dosing. Knows your grade, current chemistry, and RPT result before you finish typing.
Intelomelt Alu
Melt Log
Log each cast with: charge mix, spectrometer reading, degassing time, grain refiner added, modifier added, melt temp, pour temp, cast weight, and RPT density index. Full traceability per shift.
Intelomelt Alu
Alu Dashboard
Production KPIs: casts/day, yield%, dross%, RPT trend. Quality KPIs: defect rate by type, chemistry compliance%. Cost per tonne by grade. Period filter from daily to quarterly.
Intelomelt Alu
Defect Intelligence
Log porosity, shrinkage, cold shut, oxide inclusions, die soldering. Correlate defects with chemistry, RPT index, melt temp, and degassing time. AI-powered root cause suggestions per defect pattern.
Alu-Specific
Intelomelt Alu
AutoWatch Spectro
Monitors a folder for new Metal Power or Bruker OES export files. Automatically imports and links spectro results to the open melt record — no manual step, no typing errors.

Pre-loaded aluminium grades

ADC12 LM6 LM24 LM25 A380 A356 A319 LM4 LM27 6061-T6 7075-T6 + Add your own
How It Works — Iron & Steel

From charge plan to
melt report in 6 steps.

The same workflow your operators follow today — but calculated, not guessed.

01
Select Your Grade
Pick from the pre-loaded grade library or your own. Aim chemistry, min/max limits, and hardenability class loaded automatically.
02
Build the Charge
Add scraps, returns, and pig iron by weight. Predicted bath chemistry updates live with every entry — green within aim, red outside spec.
03
Optimise or Calculate
Click Optimise to find the cheapest valid blend automatically, or Calculate to see the full charge cost, predicted chemistry, and ladle additions.
04
Enter Spectro Result
After the half-sample, enter Bruker or Metal Power readings. Trim correction calculates the exact alloy additions needed to bring every element within limits.
05
Trim and Tap
Add exactly what the system specifies. If total additions exceed 2% of furnace weight — the industry resample rule — a rebath alert fires automatically.
06
Print and Log
One click prints your melt report. The heat is saved automatically with full traceability — every charge item, spectro, operator, temperature, and addition.
How It Works — Intelomelt Alu

Aluminium melt workflow —
from charge to RPT in 7 steps.

Handles the full aluminium melt cycle including degassing, grain refining, and modification — not just charge calculation.

01
Select Grade & Furnace
Choose from ADC12, LM6, A356, and more. Chemistry targets, Fe contamination limits, and Mg volatility corrections load automatically.
02
Build Alu Charge
Mix primary Al ingot, ADC12 returns, extrusion scrap, and master alloys. Predicted Si, Cu, Mg, Fe chemistry updates live. Fe alert fires as contamination approaches limit.
03
LP Trim — Half Furnace
Enter half-furnace OES result. LP solver calculates minimum AlSi20, AlCu50, or AlMg10 additions in kg. Mg over-addition auto-corrected for 15% burn-off.
04
Degas & Grain Refine
Log N₂/Ar degassing. Get AlTiB rod length to add. Start the modifier fade timer — live countdown shows remaining Sr effectiveness before casting window closes.
05
RPT Density Index
Enter Reduced Pressure Test result. System flags if density index exceeds 2%. Trend chart shows RPT history — catch recurring porosity patterns before they reach the customer.
06
Cast & Log
Record pour temp, cast weight, and shift details. All data — charge, spectro, RPT, degassing time, GR addition — saved automatically to the melt log.
07
Print Batch Report
One-click branded batch report with chemistry table, RPT result, grain refiner and modifier additions, and cost breakdown. Traceable, professional, in under 10 seconds.
5–15%
Alloy Cost Savings
From LP-optimised trim corrections replacing conservative manual estimates
Any
Grade Supported
Iron, steel, and aluminium grade libraries. Add your own grades at any time.
<2s
LP Solve Time
Charge optimisation and trim correction across your full material library
5 wks
Typical Payback
Based on 4 heats/day at 1% yield improvement and AUD 4/kg metal value
From the Melt Shop

Before Intelomelt, every charge was a best guess. Now the chemistry is predicted before we light the furnace, trim corrections take seconds, and the heat log gives us full traceability across every heat. The system paid for itself in the first month.

C
Senior Metallurgist
Senior Metallurgist · Iron and Steel Foundry
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Your next heat is a better one.

Set up in under an hour. Free 30-day trial.
If it doesn't improve your yield and reduce your trim cost — there's no charge.

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No obligation · Iron, steel, and aluminium · Works offline · Free 30-day trial — contact us for pricing