Client Overview
Client: Srivari Alloys
Industry: Metal & Alloy Manufacturing
Location: Srivari Alloys, Kakkalur Industrial Estate, Kakkalur, Tamil Nadu 602003
Solution Deployed: Furnace Monitoring System integrated with PID Temperature Controllers and NTS IoT Gateway
Overview
Srivari Alloys is a leading manufacturer of alloy castings, operating multiple induction furnaces for metal melting and production. Since furnace temperature and energy consumption directly impact product quality and operational efficiency, the company required a smarter way to monitor its furnace operations.
To improve visibility and process control, Niraltek deployed an Industrial IoT-based Furnace Monitoring System integrated with the existing PID Temperature Controllers and the NTS IoT Gateway. The solution enables real-time monitoring of three induction furnaces with capacities of 200 kg, 300 kg, and 500 kg. Each furnace is connected to its own PID Temperature Controller, which continuously monitors the Actual Metal Temperature and Actual Coil Temperature. The collected data is transmitted through the NTS IoT Gateway to a centralized cloud dashboard, making the Furnace Monitoring System a complete solution for real-time monitoring, energy analysis, and process control.
Project Objective
The objective was to implement a centralized monitoring solution that provides real-time visibility into furnace operations while reducing manual monitoring and improving production efficiency.
The project focused on:
- Monitoring the metal melting process in real time.
- Tracking energy consumption of each induction furnace.
- Monitoring Actual Metal Temperature and Actual Coil Temperature.
- Integrating PID Temperature Controllers with the NTS IoT Gateway.
- Generating instant alerts for abnormal temperature conditions.
- Providing centralized monitoring through a cloud dashboard.
- Supporting data-driven operational decisions.
Business Challenges
Before implementing the solution, Srivari Alloys faced several operational challenges that limited process visibility and efficiency.
- Manual monitoring of furnace temperatures increased operator workload.
- Limited visibility into energy consumption made efficiency analysis difficult.
- Temperature deviations could not be identified immediately.
- Data from multiple furnaces was not available on a centralized platform.
- Delayed response to abnormal conditions increased the risk of production interruptions.
- The facility required a Furnace Monitoring System with reliable Industrial IoT connectivity for continuous monitoring.
Furnace Monitoring System Solution
Niraltek implemented an intelligent Furnace Monitoring System to continuously monitor furnace performance, temperature, and energy consumption across all three induction furnaces.
Each furnace is equipped with a dedicated PID Temperature Controller that monitors Actual Metal Temperature and Actual Coil Temperature during the metal melting process. The collected data is transmitted to the NTS IoT Gateway, which acts as the central communication hub.
Supporting Wi-Fi, Ethernet, and GSM SIM connectivity, the gateway securely transfers operational data to the cloud platform. It also features built-in offline data storage, ensuring no critical information is lost during temporary network interruptions.
The solution provides operators with a centralized dashboard for real-time monitoring, historical trend analysis, automated reporting, and instant alerts whenever configured temperature limits are exceeded.
Key Components
- Furnace Energy Monitoring System
- Three Induction Furnaces (200 kg, 300 kg & 500 kg)
- Dedicated PID Temperature Controllers
- NTS IoT Gateway
- Energy Consumption Monitoring
- Centralized Cloud Dashboard
- Real-Time Alerts & Notifications
- Historical Reports & Trend Analysis
Solution Architecture
The Furnace Monitoring System follows a simple Industrial IoT architecture that enables secure communication between the induction furnaces, dedicated PID Temperature Controllers, the NTS IoT Gateway, and the cloud platform for real-time monitoring and process control.
200 kg Induction Furnace ──► PID Temperature Controller ─┐
│
300 kg Induction Furnace ──► PID Temperature Controller ─┼──► NTS IoT Gateway
│ (Data Collection &
500 kg Induction Furnace ──► PID Temperature Controller ─┘ Communication)
│
Wi-Fi / Ethernet / GSM SIM
│
▼
Cloud Platform
│
▼
Centralized Monitoring Dashboard
Each induction furnace is connected to a dedicated PID Temperature Controller, which continuously monitors the Actual Metal Temperature and Actual Coil Temperature. The collected data from all three furnaces is transmitted to the NTS IoT Gateway, which acts as the central communication hub. Supporting Wi-Fi, Ethernet, and GSM SIM connectivity, the gateway securely transfers operational data to the cloud platform while storing data locally during temporary network interruptions. Once connectivity is restored, the stored data is automatically synchronized with the cloud. The centralized monitoring dashboard provides operators with real-time process visibility, energy consumption analysis, historical trends, and instant alerts for better operational decision-making.
Key Solution Features
The implemented Furnace Monitoring System provides a centralized platform for monitoring furnace operations, improving process control, and supporting efficient production management.
Multi-Furnace Monitoring
The solution provides centralized monitoring for three induction furnaces (200 kg, 300 kg, and 500 kg), enabling operators to monitor temperature, energy consumption, and process performance from a single dashboard.
Real-Time Furnace Energy Monitoring
The system tracks the energy consumption of each furnace individually, enabling operators to analyze energy usage and identify opportunities to improve efficiency.
PID Temperature Monitoring
Each furnace is equipped with a dedicated PID Temperature Controller that continuously monitors Actual Metal Temperature and Actual Coil Temperature, helping maintain stable melting conditions.
Instant Alerts
Temperature thresholds can be configured based on operational requirements. The PID Temperature Controller automatically regulates the heating process to maintain the set temperature. If the Actual Metal Temperature or Actual Coil Temperature exceeds the configured limit, the system generates real-time alerts for immediate action.
Reliable Industrial Connectivity
The NTS IoT Gateway supports Wi-Fi, Ethernet, and GSM SIM connectivity, ensuring secure communication between the furnaces and the cloud platform. Its offline data storage feature prevents data loss during temporary network interruptions.
Automatic Temperature Control
The PID Temperature Controller allows operators to set the required temperature for each induction furnace. Once the set temperature is reached, the controller automatically regulates the heating process and generates an alert if the temperature exceeds the configured limit.
Implementation
The Furnace Monitoring System was deployed in four simple phases to ensure smooth integration without affecting production.
Site Assessment
The existing furnace setup and PID Temperature Controllers were evaluated to determine monitoring requirements and communication needs.
System Integration
Each induction furnace was connected to its dedicated PID Temperature Controller, which was integrated with the NTS IoT Gateway for secure data collection.
Platform Configuration
The cloud dashboard was configured to display real-time operational data, historical trends, and automated alerts. Temperature thresholds were also set according to operational requirements.
Testing & Validation
The complete system was tested under production conditions to verify communication, data accuracy, and dashboard performance before being put into regular operation.
Business Outcomes
After implementing the Furnace Monitoring System, Srivari Alloys improved operational visibility and process control across its manufacturing facility.
Key Outcomes
- Centralized monitoring of three induction furnaces.
- Continuous monitoring of Actual Metal Temperature and Actual Coil Temperature.
- Better visibility into furnace energy consumption.
- Faster identification of abnormal operating conditions.
- Improved control over the metal melting process.
- Reduced manual monitoring efforts.
- Reliable Industrial IoT communication.
- Improved operational efficiency through real-time insights.
Before vs After Implementation
| Before | After |
| Manual furnace monitoring | Real-time centralized monitoring |
| Limited process visibility | Live monitoring of all furnaces |
| Manual temperature observation | Continuous PID temperature monitoring |
| Delayed identification of issues | Instant temperature alerts |
| Separate monitoring systems | Single centralized dashboard |
| Limited energy tracking | Real-time energy consumption monitoring |
Key Business Benefits
The Furnace Monitoring System helped Srivari Alloys improve monitoring capabilities and streamline furnace operations.
Benefits
- Improved process visibility.
- Better furnace performance monitoring.
- Enhanced energy management.
- Faster response to abnormal conditions.
- Reduced manual intervention.
- Improved production consistency.
- Data-driven operational decisions.
- Scalable Industrial IoT solution for future expansion.
Conclusion
By implementing Niraltek’s Furnace Monitoring System, Srivari Alloys successfully modernized its furnace monitoring process with real-time data, centralized visibility, and intelligent alerts. The integration of PID Temperature Controllers with the NTS IoT Gateway enables continuous monitoring of temperature and energy consumption while ensuring reliable communication through Wi-Fi, Ethernet, and GSM SIM connectivity.
The centralized dashboard provides operators with actionable insights that support faster decision-making, improved process control, and better operational efficiency. This solution establishes a strong foundation for smarter, more connected manufacturing while supporting consistent product quality and optimized furnace performance.