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Real‑time material tracking for hot‑rolling mills

SCADA‑driven inventory visibility

From coil entry to slab dispatch — RFID portals, crane control loops, and a unified software core that eliminate blind spots in heavy steel production.
99.7%Read accuracy at portal gates
5 mmCrane positioning tolerance
80%Faster inventory reconciliation
35%Reduction in crane idle time
OPC UA / REST API Integrates with existing ERP and MES — no rip‑and‑replace

RFID Portal — Entry Gate

Duplicate tag alert on coil #4409. Tag ID 0x3A7F and 0x3A80 both read at 09:40:12. Possible tag collision or damaged tag.

Check physical tag on coil #4409. If damaged, replace and re-scan. Update SCADA with new tag ID.

Tag replaced. New ID 0x3A81. Coil #4409 now correctly associated. Duplicate alert cleared.

Confirmed. Portal reader re-synced. No further anomalies in last 5 minutes.

Trusted by mill operators worldwide

Real feedback from engineers and plant managers who rely on our tracking systems daily.

“The RFID portal cut our coil reconciliation time from four hours to under twenty minutes. No more clipboard chasing.”

Sirish Rai Senior Process Engineer, Tata Steel

“We integrated the crane control loop with our existing SCADA in two days. Positioning accuracy is within 3 mm even with 30-ton coils.”

Saurabh Ram Ramanathan Automation Lead, JSW Steel

“The Material Tracking SCADA Core gave us a single pane of glass across three slab yards. Our bottleneck detection now runs on live data.”

Tarun Faisal Ghosh Plant IT Manager, SAIL

“We deployed the portal readers at five entry gates. Tag read rate is 99.8% even at full production speed. Maintenance is minimal.”

Mukul Virk Operations Director, ArcelorMittal

“The audit trail from the crane control loop saved us during a quality investigation. Every lift is logged with timestamp and weight.”

John Rao Joshi Quality Assurance Manager, NLMK

Frequently asked questions

Common queries about real-time material tracking, RFID portal integration, and crane control loop setup for steel coil and slab batch management.

How does the RFID portal reader handle multiple tags at once?

The RFID Portal Reader Pro uses anti-collision algorithms that allow it to read up to 200 tags simultaneously, even at conveyor speeds of 60 km/h. Each tag is uniquely identified and timestamped before the data is pushed to the SCADA core via OPC UA.

What accuracy does the automated crane control loop achieve?

The closed-loop system positions grabs within 5 mm using laser rangefinders and encoder feedback. It compensates for load sway and thermal expansion of rails, ensuring consistent placement in slab yards and coil storage areas.

Can the SCADA core integrate with our existing ERP system?

Yes, the Material Tracking SCADA Core exposes REST APIs and supports message queue integration (MQTT, AMQP) for real-time data exchange with ERP and MES platforms. Custom adapters can be built for legacy systems.

What happens if the network connection to the SCADA server drops?

Each RFID portal reader and crane controller has local buffering capability. Data is stored on-device and automatically synced when the connection is restored. The SCADA core reconciles timestamps to maintain a continuous audit trail.

Is the system suitable for outdoor slab yards with extreme temperatures?

All hardware components are rated for -20°C to +60°C ambient temperature. The RFID readers have IP67 enclosures, and crane controllers are housed in NEMA 4X cabinets. The software runs on industrial-grade servers with redundant power supplies.

How long does it take to deploy the full tracking system in a medium-sized plant?

Typical deployment for a plant with 4 portal readers and 2 crane control loops takes 8 to 12 weeks. This includes site survey, hardware installation, network setup, SCADA configuration, and operator training. Parallel runs with existing systems are supported during cutover.

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