Tag: mecorad

At mecorad, we are committed to pushing the boundaries of precision and transparency in industrial processes. One of our latest achievements marks a decisive step forward: the successful integration of our radar sensor system into a Tetronics plasma furnace at Helmholtz-Institut Freiberg für Ressourcentechnologie. This innovation creates the foundation for safe and reliable level measurement during even the most demanding melting processes.

Integration into the furnace environment

The radar sensor was directly integrated into the lid of the plasma furnace. Its stainless-steel housing ensures durability under extreme thermal and mechanical stress. To safeguard reliable operation, special refractory materials and a tailored thermal management solution were employed.

Power is supplied efficiently via Power over Ethernet (PoE), reducing cabling complexity and simplifying system setup.

Data for safe operations

During operation, the radar sensor continuously provides level values and sensor temperature data directly to the furnace control system. This seamless transfer of data ensures operators always have a real-time overview of the melt level, enhancing both process stability and safety.

Proven in practice

Several melting campaigns have already been successfully completed with radar-based level measurement. These results confirm the reliability of the system and underline its value as the first step toward greater transparency during melting processes.

Looking ahead: Unlocking more process data

While level measurement is a crucial milestone, it is only the beginning. The next development stages at mecorad will focus on enabling access to additional process information in real time. This will give operators deeper insights and greater control over their processes, ultimately improving safety, efficiency, and performance.

Conclusion

With the integration of our radar sensor system into plasma furnaces, mecorad sets new standards for process monitoring in high-temperature environments. We are proud to contribute to making some of the most challenging industrial processes more transparent and secure—step by step.

Would you like to learn more about how our radar-based solutions can improve transparency and safety in your high-temperature processes? Get in touch with our team or explore more about our technology, such as our level series.

Cutting costs, boosting efficiency, and enabling sustainability – these are the challenges facing modern steelmaking. Conventional casting trials are often costly, time-consuming, and energy-intensive. At ESTAD 2025-European Steel Technology and Application Days, mecorad and MAGMA will demonstrate how a combination of digital twin technology and radar-based inline measurement can transform continuous casting processes, especially in stainless-steel slab production.

From trial and error to proactive process control

Traditionally, steelmakers rely on physical trials to optimize their continuous casting process. This approach consumes large amounts of energy and resources while delaying production improvements. By integrating proactive inline measurement directly at the mold exit, mecorad’s radar systems provide real-time insights into strand behavior. These measurements are fed into MAGMA’s digital twin simulations, enabling predictive analysis and continuous optimization without repeated physical trials.

The result is robust process stability, higher product quality, and significant reductions in both energy use and costs. In times of rising energy prices and tightening sustainability requirements, these benefits are crucial for steel producers worldwide.

Joint expertise – proven collaboration

The cooperation between mecorad and MAGMA showcases how complementary expertise creates real value: radar-based measurement technologies deliver precise, real-world data, while simulation models use this input to refine and forecast process performance. Together, this approach unlocks new dimensions of efficiency and sustainability in continuous casting.

Join us at ESTAD 2025

The joint work of mecorad and MAGMA will be presented in detail at ESTAD 2025 in Stockholm. Don’t miss the technical presentation:
“CC Process Optimization through Combined Digital Twin and In-line Measurement Technology for a Stainless-Steel Slab Production” – October 8, 2025, 17:10.

Be part of the discussion on how digitalization, measurement precision, and process simulation are reshaping the future of steel production.

Get to know more about our solutions for continuous casting or visit our other products and find out what we offer for level and freeboard measurement, detection or distance measurement.

mecorad´s CEO Dr. Marc Banaszak talks about the motivation behind mecorad’s products. Also, he introduces the continuous casting solution and opens up on learnings from the pandemic.

You can find the full article also here (German version only). Or have a look at the latest issues of STAHL + TECHNIK and STEEL + TECHNOLOGY.