Meltshop Simulator
Before you invest in more capacity, you need to know where the real bottleneck is.
Real plant capacity is often lost where no one is looking
In most meltshops, the problem isn't equipment shortage. The crane is waiting on the ladle, the ladle is waiting on the furnace, and the furnace is waiting on scrap charging. Each delay may only cost a few minutes, but repeated across hundreds of heats, it reshapes the plant's real capacity.
The trouble is that these bottlenecks stay hidden inside day-to-day production. While the plant is running, it's hard to tell which delay is structural and which is incidental, and without that distinction, any capacity investment is probably solving the wrong problem.
Alvand Technic's Meltshop Simulator isn't built around simulation software. It's built around steelmaking process knowledge, industrial simulation, and real operating experience in melting units.
Alvand Technic's Meltshop Simulator is an interactive simulation your team can run, question, and use as a decision-making tool.
Unlike static analysis, Discrete Event Simulation (DES) reconstructs how the plant behaves over time. Delays, queues, resource conflicts, and shift changes all show up in the model, the same factors that actually determine a meltshop's real capacity.
We build a digital model of the meltshop's operating flow, from crane cycles and ladle movement to Tap-to-Tap time and scrap yard logistics, then calibrate it against real plant data. Model parameters are set from process knowledge, operating constraints, and actual equipment behavior, not general assumptions, which is why the results hold up for investment decisions.
From there, we test scenarios: added capacity, layout changes, new equipment. Every scenario returns a number you can act on. The investment decision no longer rests on a guess.
Deliverables typically include:
Calibrated DES mode
Bottleneck analysis report
Scenario studies
Capacity roadmap
CAPEX optimization input
Not sure where your plant's real bottleneck is?
Let's find it before you commit to expanding capacity.
Wondering if we've modeled a plant like yours?
References from steel and non-ferrous meltshops are available on request.