Improve repeatability
Give operators, metallurgists and QC a shared calculation workflow independent of individual experience.
Deterministic foundry software
Trusted since 2000
Charge calculation and melt correction software for foundries
Control the Chemistry. Control the Cost.
Plan charges and calculate alloy additions using your product limits, source materials and spectrometer results with ChargeCalc.
~6Mcritical metallurgical calculations
~15M testimated lifetime metal volume supported
650k+ tannual capacity represented by public customer data
Global reachdiversified alloy and process footprint
Long-term customer trust
Trusted in foundry production since 2000.
Long-term users cite consistent calculations, repeatable quality and better control of alloy additions.
The production risk
Manual calculation is vulnerable under pressure.
In many foundries, charge preparation still depends on operator experience, spreadsheets and repeated correction cycles. That workflow becomes fragile when scrap chemistry, alloy prices, charge masses and shift teams keep changing.
Fluctuating scrap chemistry and alloy prices.
Changing charge masses and multiple products.
Shift changes requiring repetitive calculation logic.
Wrong calculations can lead to unnecessary alloy consumption, delayed pours and rejected melts.
The deterministic solution
Configured metallurgical logic - not guesswork.
ChargeCalc uses product limits, source-material data, source/product yield factors and actual OES analysis to provide a structured calculation environment where identical input conditions produce identical, documented behaviour.
Reduce avoidable cost
Use source materials more intelligently by calculating masses against exact chemistry targets and cost assumptions.
Support charge and melt traceability
Connect charge planning, OES analysis, correction decisions and final production documentation.
Connecting the decision chain
Built for production, metallurgy and QC.
Management
Cost & RiskBetter control over material cost, chemistry risk and process repeatability. ROI is driven by reduced alloy waste and lower process risk.
Production
ExecutionClear printed or on-screen charging and addition instructions at the furnace. Less ambiguity and fewer mistakes.
Metallurgy
StrategyTransforms metallurgical expertise into repeatable calculation logic with controlled limits and source/product yield factors.
QC / Laboratory
ComplianceLinks OES analysis directly to controlled correction decisions with traceability from sample to pour.
The ChargeCalc ecosystem
One workflow from planned charge to final pour.
ChargeCalc supports the operational chain that connects production planning, furnace charging, OES analysis, melt correction and documentation.
PlanPlan charges and assign product, mass and furnace.
Design
(ProdCalc)Initial charge optimization before melting.
(ProdCalc)Initial charge optimization before melting.
Charge the furnacePhysical charging and melting.
MeasureOES spectrometer analysis.
Adjust
(AdjCalc)Alloy optimization based on OES analysis.
(AdjCalc)Alloy optimization based on OES analysis.
Verify
(Schedule)Document calculations, analysis and melt status.
(Schedule)Document calculations, analysis and melt status.
Final pourFinalized and documented production.
Software modules
Initial charge design
Melt correction
Workflow support
Built for production, metallurgy and QC.
Use ChargeCalc as a focused adjustment tool or as a complete production charge calculation suite, depending on the workflow requirement.
ProdCalc
Transforms metallurgical know-how into an optimized, executable furnace recipe before melting begins.
- Built-in product specifications and chemistry limits.
- Optimized scrap and alloy mix against target chemistry.
- Target charge mass, available source materials and source/product yield factors.
AdjCalc
Replaces repeated correction cycles and tribal knowledge with deterministic, analysis-linked correction decisions.
- OES integration and instant out-of-spec flagging.
- Predicted chemistry after recommended additions.
- Precise, cost-optimized addition recommendations for operators.
Schedule
Closes the loop between production planning, furnace execution and quality-control documentation.
- Planned charges, products (alloy grades) and furnace allocation.
- Links OES samples directly to the charge.
- Tracks each charge from initial calculation to final pour.
The production risk
The practical risk of uncontrolled calculation methods.
After the workflow and modules are clear, the risk becomes easier to see: spreadsheets and generic AI do not provide the same controlled, repeatable and documented calculation environment.
| Capability | Manual / Spreadsheet | Generic AI | ChargeCalc |
|---|---|---|---|
| Repeatable logic | Partial | Variable | Strong |
| Product (alloy grade) database | Manual | Not native | Built in / configured |
| Source Material database | Manual | Not controlled | Built in / configured |
| Source and product yield factors | Manual | Not controlled | Built in / configured |
| OES workflow integration | Rare | No | Available / configurable |
| Production printout | Manual | No | Yes |
| Deterministic calculation | Depends on file/user | No | Yes |
ROI first
How quickly can ChargeCalc pay for itself?
The strongest business case is usually not the software itself. It is the effect on alloy usage, correction time, repeatability and process risk. ChargeCalc is positioned to help management evaluate payback using the foundry’s own products (alloy grades), source materials and OES workflow.
Lower alloy overuse
Reduce avoidable additions by calculating against exact chemistry targets instead of rule-of-thumb overcorrection.
Fewer correction loops
Use predicted chemistry after additions to reduce repeated correction cycles and shorten the path to final chemistry.
Less operator dependency
Replace fragile spreadsheet habits and tribal knowledge with a configured, repeatable calculation method.
Better process control
Reduce production risk through documented calculations, traceable analysis and a clearer decision chain.
Spectrometer compatibility
First confirm the data path, then calculate with confidence.
ChargeCalc can be configured around file-based OES export and import routines from widely used instrument manufacturers, linking measured chemistry directly to charge design, melt correction and documentation.
Credibility and reach
International footprint across demanding alloy production.
ChargeCalc has supported a diversified customer footprint across steel, iron, aluminium, bronze and copper alloys in demanding production environments.
~6 millionTotal critical metallurgical calculations performed.
~15M tEstimated lifetime metal production supported by ChargeCalc.
650k+ tAnnual capacity represented by publicly available historical customer data.
ChargeCalc in multiple languagesDelivered in English and 20 additional customer languages.
Customer references
Long-term customers describe the practical value in their own words.
Valmet has used ChargeCalc since 2000. Non-Ferrous Metal Works (SA) has used it since 2015.
ChargeCalc user since 2000“We have used ChargeCalc since 2000, and it has become a reliable part of our foundry workflow. It supports consistent calculations, repeatable quality and better control of alloy additions.”
ChargeCalc user since 2015“We have used ChargeCalc since 2015, and it has become a trusted part of our foundry workflow. By providing consistent calculations, repeatable quality, and better control of alloy additions, it helps us use alloying materials more efficiently, reducing waste, supporting cost savings, and improving overall production efficiency.”
Trusted since 2000
ChargeCalc supports repeatable foundry workflows where calculation consistency, alloy-addition control and production efficiency matter every day.
Evaluate with real data
Do you want to control the cost?
The best way to evaluate ChargeCalc is with your own products (alloy grades), source materials and OES workflow. Alutron can help estimate where ChargeCalc will reduce cost, correction time and process risk in your specific environment.
- CompanyAlutron AB, Stockholm, Sweden
- Emailsales@alutron.com
- Webwww.alutron.com
- WhatsApp+46 720 33 1900