Steel

When Caster Breakouts Break the P&L: Ending Sequential Troubleshooting in the Melt Shop

Name: CamelCase Collective
Price range: $

When a caster breakout occurs, the real damage isn’t just scrap—it’s lost throughput, diverted experts, and slow diagnosis. Discover how AI can replace biased, step-by-step root cause hunts with holistic, high-confidence diagnosis for continuous casting.

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Machine Learning

This is Where Your Steel Mill Is Bleeding >$1.5M Annually

Steel mills are losing millions annually through inefficient alloy optimization systems that over-alloy by 15-20%. Although most plants have existing alloy optimization initiatives, traditional statistical methods and internal machine learning projects fail due to data complexity, model degradation, and lack of transparency. Advanced white-box ML systems with real-time adaptation have proven to reduce alloy costs by $3+ per ton while improving quality consistency by 15% and reducing environmental impact. Successful implementation requires gradual deployment, operator training, and change management strategies documented in an award-winning technical research paper by Gerdau and their partner Fero Labs, showing sustained results across thousands of production heats. Key Benefits: $3/ton alloy cost reduction • 15% quality improvement • 66% process capability enhancement • 500K+ lbs material waste elimination • Real-time mechanical property prediction • Automated model maintenance • White-box transparency for operator trust

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Steel

Linear vs. Non-Linear Regression in Steel: Why In-House Linear Models Leave Money on the Table (How Fero Labs Closes the Gap)

Discover why legacy linear models underperform in steelmaking—and how Fero Labs’ explainable, non-linear AI analyzes 3+ years of data in seconds to boost yield, reduce cost, and optimize operations.

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Press Release

Fero Labs Now Available in Microsoft Azure Marketplace for Faster Steel Mill Deployment of AI

Microsoft Azure customers worldwide now gain access to Fero Labs software to take advantage of the scalability, reliability and agility of Azure to drive application development and shape business strategies. Customers can now scale and deploy the power of industrial AI across multiple production facilities at unprecedented speed.