Precimeter Control AB blog

The Case for Connected Cast House Equipment

mads.selvig@precimeter.com (Mads Alexander Selvig) — Mon, 20 Apr 2026 09:31:20 GMT

Why Industrial Ethernet Communication is the Foundation of Reliable Molten Metal Level Control

In any cast house, consistency is everything. The quality of the final product depends on dozens of variables held within precise tolerances, simultaneously, across every stage of the casting process. Among these, molten metal level control stands out as one of the most consequential. When the level drifts, the consequences reach far beyond a single casting.

The Cost of Instability

Inconsistent molten metal level is one of the most common root causes of casting defects. The reasons are well understood in the industry. When the level in a launder or mould fluctuates beyond acceptable limits, the filling rate changes. Turbulence increases. Oxide formation accelerates. Surface quality deteriorates. In DC casting operations, unstable levels during the critical filling phase can lead to cold shuts, porosity, or uneven grain structure throughout the ingot.

For operators on the floor, an unstable level demands constant attention. Manual adjustments introduce new variables. Each intervention, however skilled, carries a degree of uncertainty that an automated system does not. Over the course of a production run, these interventions accumulate. Process repeatability is compromised. The window for human error widens.

The economic consequences are tangible: increased scrap rates, higher energy consumption through unnecessary remelting, unplanned downtime, and reduced throughput. None of these outcomes are inevitable.

Why Communication Speed Determines Control Quality

Reliable level control depends on more than the accuracy of the sensor or the mechanical precision of the actuator. Those qualities matter, but they are rendered ineffective if the data transfer between them is slow or unreliable.

Consider what happens in practice. A laser camera sensor detects a deviation in the molten metal level. That measurement must travel through the communication interface to the control system, which processes the data, calculates the required correction, and sends a command to the actuator. The actuator then responds. From detection to correction, every millisecond of delay translates into additional process variation.

In traditional setups using analogue signal transmission or older serial communication protocols, that delay is a known limitation. The signal travels. The PLC reads it on its next scan cycle. The actuator receives its instruction on the following cycle. By the time the correction is made, the process has moved on. The control system is, in effect, always reacting to a past state of the process rather than its present one.

Industrial Ethernet changes this fundamentally.

How Industrial Ethernet Closes the Loop

Protocols such as PROFINET and EtherNet/IP are designed for deterministic, high-speed data exchange in industrial environments. Unlike analogue signals, which carry a single value at a fixed resolution, Industrial Ethernet transmits structured data packets with timestamps, status information, and diagnostic data, all in real time.

When a Precimeter sensor communicates via Industrial Ethernet, the level measurement is transferred directly to the PLC within a single network cycle, typically in the range of one to ten milliseconds depending on the configuration. The control system reacts immediately. The actuator receives its correction command without lag. The process remains stable.

This is not an incremental improvement. It is a structural change in how responsive the control loop can be. The faster and more reliably the data flows, the tighter the control. The tighter the control, the more consistent the cast house output.

The Integration Advantage

Beyond raw speed, Industrial Ethernet brings a further benefit that is increasingly important in modern cast house operations: seamless integration with existing automation infrastructure.

Most contemporary PLCs and SCADA systems are designed around Industrial Ethernet as the primary communication standard. When sensors and actuators speak the same protocol as the broader control network, integration is straightforward. There are no interface converters to maintain, no signal conditioning boxes to calibrate, and no analogue wiring to troubleshoot.

This matters practically. A cast house adding new sensors or upgrading actuators should be able to connect them to the existing network without redesigning the control architecture. Precimeter sensors and actuators support PROFINET, EtherNet/IP as standard or optional interfaces, meaning they can slot into most production environments without requiring significant additional engineering.

The result is a control system that scales as operations grow. A single sensor controlling a launder level today can be joined by additional sensors at the furnace tap out, at the mould level, and across the distribution system, all integrated into a unified control loop that manages the entire casting process from a single interface.

A Foundation for Further Automation

Connected cast house equipment is also the foundation on which further automation is built. The data generated by Industrial Ethernet-connected sensors and actuators, position values, level measurements, temperature readings, alarm states, flow corrections, does not simply serve the immediate control loop. It accumulates as a process record.

Plant engineers can analyse this data to identify patterns, refine casting recipes, schedule predictive maintenance, and optimise process parameters over time. The transition toward Industry 4.0 in aluminium production requires precisely this kind of structured, timestamped data flowing from the process floor into analysis tools. Cast houses that invest in connected equipment now are building the data infrastructure that will support continuous improvement for years ahead.

The Precimeter Approach

Precimeter sensors and actuators are designed with Industrial Ethernet integration as a standard consideration, not an afterthought. The ProH laser camera sensor family, the ProH Twin Delta for slab mould applications, the ProLAD for launder and furnace environments, and the full range of actuators, including the TXP-10 tap out, the PXP-2EM pin position, and the GXP-10 gate valve, all support PROFINET and EtherNet/IP.

This means that a complete level control solution, from sensor through actuator, controlled by an MLC-A1 single-point system or a customised MLC-ADV installation, can be built on a single communication protocol, integrated cleanly into the PLC architecture that already governs the rest of the production line.

For cast houses evaluating upgrades to their level control systems, the communication layer is where the investment in precision is either preserved or lost. A highly accurate sensor feeding data through a slow or unreliable interface cannot deliver the control quality the sensor itself is capable of. Industrial Ethernet removes that bottleneck.

Starting the Conversation

If stability in your casting process is a priority, and the communication architecture connecting your sensors and actuators to your control system has not been recently reviewed, it is worth examining whether the current setup is limiting the performance you are already paying for.

Precimeter works with cast houses at every stage of automation, from initial integration to full system upgrades, and can advise on the most appropriate communication configuration for your specific process and PLC environment.

Interconnected DC Casting – Boosting Safety, Sustainability, Profitability and Efficiency

mads.selvig@precimeter.com (Mads Alexander Selvig) — Mon, 23 Mar 2026 08:55:08 GMT

Many aluminum casthouses today want higher production volumes, stricter quality standards and more sustainable practices. Often, steps in molten metal handling are run separately, which can increase scrap, safety risks and response delays. By uniting level sensors, flow control actuators and a shared control system into a single data-driven setup, cast houses can improve overall consistency, protect workers and streamline the path from furnace to mold. Gränges in Finspång, Sweden, offers an example of how these ideas can deliver strong and positive outcomes.

Unifying the DC Casting Process

In a typical direct-chill casting operation for extrusion billets or rolling slabs, molten aluminum travels from the furnace through troughs before entering molds. When these stages do not communicate, minor missteps in metal levels may cause trough overflow or underfill, leading to surface flaws and production downtime. By linking equipment in one connected environment with level sensors and flow actuators, cast houses can fix most problems at once. If a sensor detects a spike in the trough or mold, an actuator adjusts the flow before a spill occurs. Overfill guards act as a final safety measure if an unexpected event appears, letting operators remain secure while production runs smoothly.

Laser and Inductive Sensors for Reliable Measurement

Accurate molten metal level monitoring is essential. Laser triangulation sensors handle intense heat and reflective surfaces in open or semi-open zones, delivering continuous measurements without physical contact. Inductive sensors excel in closed or pressurized furnaces where a laser might struggle. Both sensor types pass data to a controlled environment that alerts operators only when readings move past desired thresholds. Real-time data keeps the fill rate stable, limiting oxidation and potential cracks in the solidified product.

Automated Flow Control With Actuators

Sensors alone cannot maintain stable casting if there is no swift way to adjust molten metal flow. Motor-driven actuators serve this function, opening or closing spouts, stopper rods or gates in response to sensor input. If mold levels rise too quickly, an actuator slows the inflow. If levels fall, it reopens enough to stabilize the process. This immediate reaction frees operators from standing near hot metal. Over many hours of casting, a more balanced fill reduces flaws such as porosity or incomplete fills that otherwise lead to remelting or scrapping.

Overfill Guards Prevent Spills

Even well-tuned lines can experience a sudden surge if a sensor fails or a rare condition takes place. Overfill guards provide the last layer of defense by detecting fast increases in the molten metal level and issuing a stop command before a large overflow can happen. Such accidents harm equipment and put workers at risk. By linking overfill guards with other devices, the system reacts as a whole to protect the process.

Data Under One Roof

Without a single interface, each station might record data separately, leaving operators to compare multiple readouts. A united system collects signals from sensors, actuators and overfill guards in one place. Staff can watch different areas on one console. If logs show frequent trough spikes at a certain cast length or dips in furnace flow, engineers can pinpoint the cause and fix it. This data-based approach fosters continuous improvement by letting the plant change fill rates or refine furnace conditions as needed.

Gränges: A Practical Example

Gränges, a Swedish-based company with plants in Tennessee, Arizona and North Carolina as well as Sweden, Poland and China abroad, demonstrates how integrated DC casting can transform production. They have used laser-based sensors for monitoring molten metal levels, along with actuators to manage flow automatically. In Finspång, the company has seen fewer starting and stopping cycles, which reduces overflow or underfill problems. This shift also allowed them to lessen scrap, reduce guesswork and raise productivity by shortening re-melt cycles.

“The view of sustainability has gone from being relatively ignored to being a high priority. Awareness is snowballing, and at the same time, as we feel that it is essential to produce more sustainably, our customers agree. They now demand that we lower our carbon footprint and that our materials maintain a certain standard.” says Elin Lindfors, Production Technology Manager at the Melting Plant at Gränges Finspång.

“We continuously measure sustainability according to several parameters: our staff's well-being and security in the workplace, environmentally based on carbon footprint and energy consumption, and efficiency based on production power and speed. Many of our employees have worked with us all their lives, while many are new employees. We work intensively to engage the entire workforce to operate sustainably, retain the community and build strong teams.”

Gränges sees this automation as a cornerstone of daily operations. “Automatic casting is a big part of our safety and sustainability work. We started using Precimeter for this around 2006–2007. For us, it is a regular workday to let the casting go automatically. Our set-up allows us to avoid having staff in critical places at critical moments. We also increase production efficiency. In addition, it has never been a problem to teach new employees our systems with Precimeter. It is very straightforward.”

Their results confirm the gains from better flow measurement and real-time control.
“Productivity has improved a lot since we started using Precimeter lasers to measure our levels and actuators to regulate the flow. We have fewer fails and rejections because we can repeat castings several times. We also have more stable starts for each casting.”

Gränges also appreciates the close collaboration. “The collaboration with Precimeter is only positive! It is excellent to have a supplier close by and open to the intimate cooperation we have. We can get service on-site; there are fast response times and good support but also dialogue to develop solutions that suit us. Precimeter is very knowledgeable about what we want and understands the risks we may experience, which gives us peace of mind knowing that the propositions fit our needs.” Elin concludes.

Benefits in Four Key Areas

An integrated production line can add value to every step of the casting operation. By linking sensors, actuators and overfill guards in one connected system casthouses can raise safety standards, limit environmental impact, improve profits and increase efficiency. This synergy across the entire casting process leads to a more reliable operation that meets modern demands.

Safety
Operators do not need to stand close to molten metal, and overfill guards cut the danger of large spills. That reduces risks for staff and saves downtime.
Sustainability
Consistent control helps avoid scrap and slashes re-melt cycles, lowering energy use and emissions. That supports efforts to reduce the environmental footprint of casting.
Profitability
Fewer defective slabs or billets means fewer interruptions. Predictable casting schedules let managers keep orders on track and satisfy customers.
Efficiency
Automated systems adjust small deviations immediately, letting staff work on improvements or data review instead of manual tasks. Logged data can inform better casting methods over time.

A Path Toward Industry 4.0

Although stronger sensors, actuators and overfill guards are key, they also pave the way for greater Industry 4.0 capabilities. Once components share data, advanced analytics and partial automation become possible. Plants can examine logs to improve casting startups or fine-tune flow rates for different alloys without the usual trial-and-error. A steady flow of data also lets them design algorithms to minimize scrap, reduce energy usage and keep quality predictable.

A Brighter Future for Aluminum Casting

By bringing sensors, actuators, overfill guards and centralized monitoring together, DC casting becomes safer, greener and more profitable. The experience of Gränges shows that these methods can be rolled out across multiple facilities, each with different throughput and product requirements. A fully automated and integrated casting process runs more smoothly, shields employees from hazards and consistently delivers billets or slabs that match high standards. Through ongoing improvements based on data, aluminum casthouses can thrive in a marketplace that values environmental responsibility and operational excellence.

Safer, Smarter and More Sustainable Casting

mads.selvig@precimeter.com (Mads Alexander Selvig) — Thu, 05 Feb 2026 08:39:50 GMT

Precise Level Measurement for All Applications — Safer, Smarter and More Sustainable Casting

In today's aluminium industry, precision forms the foundation for safety, efficiency and sustainability. From DC casting of billets and slabs to molten metal transfer in furnaces and launders, accurate molten metal level measurement is critical for achieving consistent product quality while reducing environmental impact.

Cast Houses worldwide rely on Precimeter's laser camera sensors, purpose-built for extreme molten metal conditions. Our sensor range,including ProH, ProLAD and ProV provides cast houses with the tools needed to automate processes, reduce waste and increase both safety and output.

Why Molten Metal Sensors Drive Sustainable Casting

Automating molten metal level measurement with laser camera sensors supports long-term sustainability through:

Lower scrap and reduced remelt, cutting energy use and conserving raw materials
Steady flow and level control, improving yield and reducing casting defects
Reduced operator exposure to hot metal, enhancing workplace safety
Real-time data collection enabling predictive maintenance and better planning
More stable furnace operation, supporting energy efficiency and environmental objectives

Precimeter sensors deliver more than measurement. They enable intelligent, environmentally conscious production. By continuously tracking metal levels and integrating with actuators and control systems, these sensors create a closed-loop process supporting both precision and sustainability.

A Sensor for Every Process — From Launder to Mould

Each casting application presents unique challenges. Precimeter offers a range of laser sensors designed for different operational needs.

ProLAD – Reliable for Standard Applications
The ProLAD is a compact, dependable sensor ideal for molten metal level measurement in launders and for furnace tilt control. It delivers consistent readings even in harsh conditions with steam or surface reflection and integrates easily into existing setups.

ProH – Proven Performance in Demanding Environments
The ProH is Precimeter's most widely deployed sensor. Known for high precision and durability, it handles the heat, smoke and vibration typical in modern casthouses. With accuracy to 0.07 millimeters, It delivers exceptional performance in precision‑critical casting processes such as DC casting, continuous casting, ingot casting, and beyond.

ProV – High Precision for Advanced Automation
The ProV is designed for fast-paced, highly variable casting operations. It provides rapid response, high resolution and stable measurement even on highly reflective or turbulent molten surfaces. Utilizing violet laser technology for enhanced stability on ferrous metals and high‑temperature surfaces with red‑hot emissivity, it is ideally suited for Industry 4.0 environments and advanced casting control systems.

Smarter Casting Leads to Greener Results

By improving molten metal flow consistency and eliminating manual checks, laser camera sensors enable cast houses to operate with greater efficiency and fewer interruptions. This reduces energy waste, limits scrap and supports safe remote monitoring—all contributing to cleaner, more productive operations.

When combined with Precimeter actuators and control systems, these sensors form a complete automation solution supporting your quality, safety and sustainability objectives.

Summary

Precimeter's laser camera sensors—ProLAD, ProH and ProV—deliver precise molten metal level measurement for aluminium casting applications. Purpose-built for extreme foundry conditions, these sensors enable automated process control that reduces scrap, improves yield, enhances workplace safety and supports energy efficiency. By providing accurate, real-time measurement in launders, furnaces and moulds, Precimeter sensors form the foundation of sustainable, high-quality casting operations. When integrated with Precimeter actuators and control systems, they create complete automation solutions that advance both operational performance and environmental responsibility in modern casthouses.

Ready to Advance Your Casting Process?

Explore our full sensor range: www.precimeter.com/products/sensors
Contact our sales team: sales@precimeter.com
Learn more: www.precimeter.com/contact

Euroguss 2026

mads.selvig@precimeter.com (Mads Alexander Selvig) — Tue, 03 Feb 2026 08:02:14 GMT

The value of industry connections.

Thank you to everyone we've connected with at trade shows and conferences around the world. These face-to-face conversations remain essential to our work.

Every discussion about casting challenges and process optimization helps us better understand the evolving needs of the molten metal industry. Your insights directly inform how we develop solutions that address real operational requirements.

To the OEM manufacturers, system integrators, and end users who share their expertise with us, your collaboration drives innovation forward.

We're committed to being a reliable partner, regardless of continent or time zone. If we haven't connected yet, or you'd like to continue the conversation, our team is always available.

Contact: sales@precimeter.com

World leader in molten metal level control

Great show in Düsseldorf

Admin — Fri, 30 Sep 2022 22:00:00 GMT

Another great event has passed. Thank you to everyone who came by our booth!

The end of September marked a highlight of our year - the trade show and exhibition of Aluminium in Düsseldorf, Germany. After a few years without face-to-face events we were joyed to once again see so many people together in one space. We'd like to thank everyone who took time to come by our booth and chat with us, and if you missed us don't worry - we'll meet again soon. Or if you do not want to wait, contact us and we'll book a time to talk.

How automation sets Gränges in leading sustainability

Admin — Wed, 28 Sep 2022 22:00:00 GMT

Moving into the future of casting with sustainable automation. What is their approach to combine these values successfully? In our Customer Case Study, Gränges reveals the success factors.

As development takes place at an ever-faster pace, it is crucial to keep track of the current situation and the next steps. Foundries must live up to customers' expectations on today's standards in terms of sustainability, but preferably tomorrows. For Gränges in Finspång, sustainability has permeated the business in various ways for many years. Core values emphasising innovation, accessibility and competence make them a pioneer for modernisation in the entire industry.

The work towards optimising casting productions for sustainability began to take shape over ten years ago.

- The view of sustainability has gone from being relatively ignored to being a high priority. Awareness is snowballing, and at the same time, as we feel that it is essential to produce more sustainably, our customers agree. They now demand that we lower our carbon footprint and that our materials maintain a certain standard, says Elin Lindfors, Production Technology Manager at the Melting Plant at Gränges Finspång.

Safer and smoother

The concept of sustainability has, in turn, developed from primarily dealing with environmental aspects to including automation and personnel. Automating the production line will make each casting safer, simpler, and more sustainable.

- We continuously measure sustainability according to several parameters: our staff's well-being and security in the workplace, environmentally based on carbon footprint and energy consumption, and efficiency based on production power and speed. Many of our employees have worked with us all their lives, while many are new employees. We work intensively to engage the entire workforce to operate sustainably, retain the community and build strong teams.

Reaching business goals

Several set sustainability goals have come ever closer by automating production. Gränges has created a win-win situation by using modern solutions in casting.

- Automatic casting is a big part of our safety and sustainability work. We started using Precimeter for this around 2006–2007. For us, it is a regular workday to let the casting go automatically. Our set-up allows us to avoid having staff in critical places at critical moments. We also increase production efficiency, says Elin. In addition, it has never been a problem to teach new employees our systems with Precimeter. It is very straightforward.

Increased productivity

Automation is crucial to ensuring sustainable production as the spotlight from customers, and the industry increasingly focuses on energy consumption and efficiency. Solutions for measuring metal levels and actively controlling flows are essential to improving productivity, reducing waste and minimising energy consumption.

- Productivity has improved a lot since we started using Precimeter lasers to measure our levels and actuators to regulate the flow, says Elin. We have fewer fails and rejections because we can repeat castings several times. We also have more stable starts for each casting.

Good teamwork

High-quality solutions and good communication describe the collaboration between Precimeter and Gränges. The importance of understanding and knowledge builds a successful partnership.

- The collaboration with Precimeter is only positive! It is excellent to have a supplier close by and open to the intimate cooperation we have. We can get service on-site; there are fast response times and good support but also dialogue to develop solutions that suit us. Precimeter is very knowledgeable about what we want and understands the risks we may experience, which gives us peace of mind knowing that the propositions fit our needs, Elin concludes.

About Gränges:

Gränges is an aluminium technology company that drives the development of lighter, smarter, and more sustainable aluminium products and solutions. The company offers advanced materials that increase the efficiency of customers' manufacturing processes and the performance of the end products.

Visit us at Aluminium Düsseldorf

Admin — Thu, 18 Aug 2022 22:00:00 GMT

We will be attending Aluminium in September, the world's leading trade show for the aluminium industry.

Between the 27th - 29th September we will be showcasing our solutions at the Aluminium trade show in Düsseldorf. This is a great opportunity to meet and discuss automation solutions that can improve safety, productivity, and repeatability for your casting processes. We will bring our products to show you the benefits of our laser camera sensors, actuators and electromagnetic pumps.

Visit us in Hall 6, stand number 6F69. See you there!

Precimeter launches new website

Admin — Tue, 20 Apr 2021 22:00:00 GMT

We are proud to announce our new website. With the new design and the user-friendly layout, it will make it even easier to find information about our products and solutions.

Introducing the new Precimeter.com

We are proud to announce our new website. With the new design and the user-friendly layout, it will make it even easier to find information about our products and solutions.