Problem definition
The aluminum manufacturing industry faces numerous challenges, particularly in the delacquering process, where dross formation is a persistent issue. Dross is a byproduct consisting of im- purities and metal oxides, forms on the surface of molten aluminum and, if not detected and managed effectively, can lead to significant material loss, increased waste, and operational inefficiencies. Currently, dross detection and removal largely depend on manual inspection and experience, which introduces inconsistency and delays. These traditional methods result in frequent production interruptions, lower-quality products, and increased energy con- sumption. The need for more precise and efficient solutions in aluminum delacquering has be- come critical as manufacturers strive to optimize production, reduce waste, and improve over- all sustainability. Rising raw material costs and energy prices further intensify the pressure to minimize losses and enhance furnace efficiency. Additionally, stringent environmental regula- tions push industries to adopt technologies that reduce waste and emissions, making manual methods obsolete in meeting these expectations.
What we offer
The introduction of an automated tool for real-time dross detection addresses the pressing industry needs that the sector is facing. By utilizing advanced sensors and analytics, the tool allows for continuous monitoring of furnace conditions, ensuring early detection of dross formation. This leads to timely intervention, reducing material loss and enhancing overall pro- cess efficiency. As manufacturers aim to increase output while maintaining high-quality stand- ards, this tool provides a key technological solution, offering greater precision, lower oper- ational costs, and improved sustainability. Our product, M4DVision, is designed to enhance the efficiency and safety of aluminum delacquering by employing AI and computer vision technol- ogy to monitor the surface of the molten aluminum. By utilizing video stream from a in-furnace camera system, It continuously scans for the formation of dross, which is a by-product that needs to be removed to maintain the quality of the melted aluminum. Using advanced image recognition algorithms, the tool detects when dross is present and automatically alerts op- erators at the optimal moment to open the furnace and initiate the cleaning process. By providing real-time insights, our system helps minimize manual intervention while ensuring that the delacquering process runs smoothly. This automated monitoring not only increases productivity but also reduces the risk of errors and improves the overall quality of the final product. Additionally, the tool integrates seamlessly with existing furnace setups, mak- ing it highly usable for operators with minimal disruption to the workflow. Its intuitive interface allows operators to easily monitor furnace conditions and receive timely alerts, optimizing the cleaning and skimming procedures for maximum efficiency.
Impact
The use of M4DVision can potentially produce a positive impact in 3 different areas of the UN’s Sustainable Development Goals which can be translated to positive ESG metrics for the companies that use our solution.
