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 Aluminium 312 Grades Works Offline
Talk to Us

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

GS42CrMo4V
Heat #5542 · Furnace 2 · 4,850 kg
Live Chemistry
C
—
Si
—
Mn
—
Cr
—
Mo
—
Ni
—
—
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 in UAE and Australia

Trusted in production by

Secondary Aluminium Ingot Manufacturer
Sharjah Industrial Area — UAE
Aluminium ADC12 · LM6 · LM24 Live in Production

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

Castings Tasmania
Launceston, Tasmania — Australia
Iron & Steel Induction Furnace Pilot Partner

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

Iron and steel foundry in Australia · Secondary aluminium smelter in UAE · More clients 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 of AUD per shift in avoidable waste.

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 planned — structured input with validation eliminates errors
Self-learning recovery: system measures actual yield and auto-corrects after 20 heats
Print-ready branded melt report in one click
Features

Everything your metallurgist
needs, in one system.

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

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.
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.
Charge Optimiser
Find the cheapest scrap and returns combination that hits grade chemistry. Accounts for stock quantities, melt loss factors, and grade return limits. LP-optimised — mathematically the cheapest valid blend.
Hardenability (DI)
Grossmann Ideal Diameter and full Jominy end-quench curve calculated from actual spectro chemistry per ASTM A255. Verified against Caterpillar reference data. Know hardenability before the furnace is tapped.
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 — not just when your senior metallurgist is in. Runs fully offline.
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. Your yield predictions get more accurate the more you use it.
Unique Feature
Heat Log
Every heat saved automatically with full traceability — charge mix, half-sample spectro, final spectro, temperatures, alloy additions, operator, furnace, tap weight. Edit, reprint, or export any heat at any time.
Print Reports
One-click branded melt reports in your format — chemistry table, ladle additions, per-tap splits, deox quantities, operator sign-off. Works with your current report format. Print in under 10 seconds.
Scrap Inventory
Track scrap and alloy stock levels in real time. Auto-deducts on use. Low-stock alerts so the charge team knows what's available before planning the next heat. Reserve quantities for scheduled jobs.
Production Dashboard
Live KPIs across your operation — heats per day, yield trend, alloy consumption, chemistry trends, operator performance, DI distribution. Connects to your ERP for sales order pipeline and reject cost analysis.
Works Offline
Runs entirely on your local network. No cloud dependency, no internet required. Your heat data, grade library, and material chemistry never leave your site. Available as a Windows desktop application or local web server.
Spectro Link
Direct import of spectrometer readings from Bruker, Metal Power, and other OES systems. No manual typing — spectro results populate the trim correction screen automatically, with validation to catch transposition errors.
Coming Q4 2026
How It Works

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 312 pre-loaded grades 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 in your format. The heat is saved automatically with full traceability — every charge item, spectro, operator, temperature, and addition.
5–15%
Alloy Cost Savings
From LP-optimised trim corrections replacing conservative manual estimates
312
Pre-Loaded Grades
Iron, steel, and aluminium alloys. Add your own at any time.
<2s
LP Solve Time
Charge optimisation and trim correction across 276 materials
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
Iron and Steel Foundry · Australia
Pricing

Simple, transparent pricing.
No surprises.

All tiers include a free 30-day trial. No credit card required to start. If you don't see improvement in your first month, there's no charge.

Desktop
AUD 3,500
per year · single site
  • Windows EXE — works offline
  • Up to 3 users on local network
  • All core modules included
  • Email support (48h response)
  • One-time setup: AUD 1,500–2,500
Cloud Professional ★
AUD 8,000
per year · recommended
  • Browser access from any device
  • Unlimited users, same site
  • All modules including Dashboard
  • ERP data integration (CSV)
  • WhatsApp + email support (24h)
  • Monthly backups included
  • One-time setup: AUD 2,500–4,000
Enterprise
AUD 20,000+
per year · multi-site
  • Multiple foundry sites
  • Custom report format
  • ERP system integration
  • Priority support (4h response)
  • Quarterly review calls
  • Custom grade library migration
Free · No Obligation

Talk to a metallurgist.
Not a salesperson.

We offer a free 30-minute consultation with an experienced foundry metallurgist — no pitch, no pressure. Bring your biggest melt challenge. Whether it's chemistry inconsistency, high trim costs, yield loss, or hardenability failures — we'll work through it with you on the call.

30-minute video or phone call — with a metallurgist who has worked in iron, steel, and aluminium foundries
Bring your real problem — chemistry failures, melt loss, alloy cost, hardenability specs, grade compliance
Honest advice — if Intelomelt isn't the right fit for your operation, we'll tell you
Limited slots available — we keep this personal, not a webinar

No credit card. No commitment. Just metallurgy.

What We Can Cover
Charge mix optimisation Iron · Steel · Alu
Trim correction strategy Iron · Steel · Alu
Melt loss and yield improvement Iron · Steel · Alu
Hardenability and DI calculations Iron · Steel
Grade compliance and spec review Iron · Steel · Alu
Dross and recovery analysis Aluminium
Intelomelt live demo for your grades Optional
Sessions are conducted by a qualified metallurgist with hands-on induction furnace experience across iron, steel, and aluminium casting operations.
Start Today

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.

Email Us Directly

No obligation · Works with any induction furnace · Iron, steel, and aluminium · Starting from AUD 3,500/year