ActiveCAST

Continuous casting control and automation system

System description

ActiveCAST is Polytec’s advanced automation platform for continuous casting machines, designed to optimize every stage of the casting process, from the ladle turret to the discharge area. The system combines precise process control, intelligent automation, and real-time production tracking to improve product quality, maximize plant availability, and ensure safe and reliable operation.
Suitable for billets, blooms, and slabs, ActiveCAST integrates all key casting functions into a single automation architecture. Advanced algorithms continuously regulate steel levels, casting speed, mold oscillation, and cooling systems while monitoring process conditions to prevent breakouts and ensure consistent casting quality. The platform also manages production tracking, cut optimization, automatic start-up procedures, and marking system integration, providing complete traceability from the ladle to the storage area.

ActiveCAST

System highlights

settings

Main components

  • Complete automation for billets, blooms, and slabs
  • Ladle turret and flying tundish automation
  • Tundish and mold steel level control
  • Mold temperature monitoring with breakout detection and prediction
  • Primary and secondary cooling system control
  • Precision casting speed regulation
  • Electrical and hydraulic mold oscillator control
  • Automatic line start-up and dummy bar handling
  • Cut length and weight optimization
  • Production tracking and marking machine integration
  • Flexible setup for different casting profiles
star

Benefits

  • Increased plant productivity and operational efficiency
  • Improved casting quality through precise process control
  • Reduced accidental downtime with breakout prediction and advanced monitoring
  • Complete product traceability from casting to storage
  • Greater plant reliability and operational continuity
  • Reduced maintenance through intelligent automation and diagnostics
  • Fewer manual operations with centralized process management
  • Enhanced operator safety in critical casting areas
  • Lower operating costs (OPEX) and improved long-term performance

Technical specifications

Hardware

Based on PLC/DCS/PAC & HMI / operator panel market standard (SIEMENS, ROCKWELL, GE, B&R, BECKHOFF, ETC.)

To be agreed according to customer preferences

User-friendly graphic interface to allow operators to quickly take over and control all plant machines

Interactive diagnostics to help operators immediately identify any action blockage cause or any system anomaly

Ultra fast real-time software oscilloscope application for advanced diagnosis

Book a meeting and get a quotation

Contact us and share your preliminary request.
From feasibility study through design and implementation, we’ll support you in developing the best solution.

sales@bmgroup.com