Melt, molding, sand, pour and shakeout all produce data, and most of it is still recorded on paper. We bring that data into Ignition, where people can act on it. We did this at Ferroloy, an iron foundry in Wichita, Kansas.
Foundries combine heat, older equipment, knowledge held by a few experienced people, and data on clipboards. Many plant-floor software projects stall in that environment.
One of them spent more than 20 years at Huron Casting, where his Ignition project won an Inductive Automation Firebrand Award in 2014, and he led our Ferroloy build. You will not need to explain how a pour works in the first meeting. We are active in AFS, and Ferroloy's owner first heard from us at a Foundry 4.0 session at CastExpo 2022.
Trace each defective casting to the melt chemistry, sand and process conditions it was made under.
Find the hours lost on existing equipment before you invest in another line.
Downtime that is not recorded cannot be reduced. We set up automatic downtime capture, with stop reasons your operators understand.
Ferroloy set targets of 25 to 30% more capacity and 30 to 35% less scrap. Our foundry engineers led the build, and in 2026 owner Mark Soucie confirmed that Ferroloy had reached them. Modern Casting covered the project in March 2026.
Call us. We will connect you with the right engineer, and if we are not the right fit, we will say so.
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