In today’s competitive environment, quality, time and cost is vital for profitability.
ChargeCalc is a solution to maintain smelt quality, increase efficiency and reduce cost.
Additionally ChargeCalc helps you decrease waste adding further to your operating margins. Following are some of the ChargeCalc benefits.
Traditional charge correction is a headache-inducing process that requires operators with metallurgical proficiency. ChargeCalc takes the complexity out of charge correction, enabling operators with little or no metallurgical experience to instantly perform precise charge correction calculations. With a reliable, easy to use and fully integrated application doing all the work, unnecessary errors are avoided, quality is maintained and skilled staff resources may focus on more stressing issues.
Advanced Products and Sources
When producing alloyed metals with tight specifications, it is vital to find the correct source materials, maintain quality and keep cost down. Manual calculation practically only takes in consideration a few elements, this generally results in the use of expensive high purity alloying materials. Handling ferrous and non ferrous alloys ChargCalc product and source configuration enables the use of cheaper, lower grade source materials while maintaining quality.
Double the Saving.
ChargeCalc helps you to find the cheapest possible melt. The actual savings achieved vary depending on your source materials and products. ChargeCalc also saves you energy with the virtually instant calculation. If we calculate based on a 1 ton induction furnace casting 6 melts per day. With manual calculation estimated to 10 minutes per melt this equals to 60 min furnace idling per day. With an energy consumption of 550 KWh @ $0.15/KW this amounts to ~$82 per day. With 260 days of production per year and excluding labor cost, energy alone amounts to a total of ~$21,300!
ChargeCalc Software Suite is modular and scales to your requirements.
Whether you require AdjCalc for optimizing existing melts or if you need ProdCalc with the advanced scheduler that handles charging new melts. With multiple furnace support AdjCalc and ProdCalc may be installed on a standalone (S) PC or networked server (N).
As your requirements change the modular structure enables adding functionality by simply upgrading the license.
The ChargeCalc software suite has been developed with stability, ease of use, speed and precision in mind. Building on experience from conception in the early -90’s, with the low specification computer systems available at that time, we have continuously maintained a stable and low footprint application as to not interrupt process criticall operations. All in all this enables users in the metal industry to increase efficiency while maintaining precision and reducing cost.
Energy and Environment
Working with high volumes, mistakes are costly, time consuming and impact the environment. When the chemical composition of a melt does not match the desired specification, operators must perform a charge correction. Manual calculations often lead to unnecessary pour-outs and resulting waste.
Return on Investment
The above demonstrates how ChargeCalc can add both efficiency and value to your operations. With a typical ROI calculated in months, the question is can you afford to miss out on using ChargeCalc to your advantage?
AdjCalc – Cost Optimizing Melt Correction
- Calculates the least expensive way to correct an existing melt
- Stand alone or integrated with an analysis system
- Element limits and target
- Linear relation formulas for elements.
- Stock limits and inventory
- Yield factors
- Furnace sizes
- and more
ProdCalc – Melt Design and Scheduling
- Includes AdjCalc and dependent modules
- Calculate the least expensive way to charge a furnace
- Stand alone or integrated with spectrometer
- Fixed absolute or relative amounts of source material
- Production scheduling
- Melt design in advance
- Production log
- Sample identification transfer to Spectro/Bruker instruments for full automation
- Return material and remaining melt in the furnace