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We are therefore all the more delighted that on 12 May 2025, we had the opportunity to present the key results of our innovative cooperation project with thyssenkrupp Steel Europe and our development partner NeurologIQ GmbH on the AI-based control of hot-dip galvanising processes during a visit by North Rhine-Westphalia’s Minister President Hendrik Wüst to the ‘Summit’ in Siegen.During his visit, Hendrik Wüst emphasised the significant potential of AI applications for North Rhine-Westphalia’s production sector.
 

What was it about?
In a large-scale research project, EMG has been working with the above-mentioned partners thyssenkruppSteel Europe and NeurologiQ in recent years on the application of AI-based analysis and modelling methods for process improvement and control in flat metal production lines. The use case was the coating process in a hot-dip galvanising line. The result of this development work is the EMG iCASS® (Intelligent Control and Analytical Software Solutions) software platform – a practical solution for intelligent process control in the metals industry.

EMG iCASS® – Enabling intelligent Production through integrated Control and Analysis
EMG iCASS® is a modular and scalable software platform for supporting advanced process control and data analysis in industrial production environments. It can be seamlessly integrated into a wide range of sensors, machines and higher-level systems (such as MES or ERP) and provides the necessary basis for monitoring, analysing and optimising production processes in real time.

EMG iCASS® combines classic control logic with modern data analysis, enabling the transition from reactive to predictive and prescriptive manufacturing. Prescriptive analysis is currently the most advanced approach in the development of data-driven production. It goes beyond descriptive, diagnostic and even predictive approaches by not only predicting what is likely to happen but also recommending or automatically executing the best course of action to optimise results. This is particularly important for real-time control approaches using machine learning models in the EMG iCASS® framework.

EMG iCASS® – Example of Control in real time with AI
In the above-mentioned R&D cooperation, the performance of machine learning for real-time control in hot-dip galvanising was successfully demonstrated.During the continuous galvanising of steel strips (hot-dip galvanising), precise coating, high process stability and plant efficiency are crucial. The selected production line is equipped with an EMG eMASS® strip stabilisation system, which is integrated into the DUMA-BANDZINK air knife. 

The system is based on the EMG iCASS® platform and generates real-time pressure setpoint recommendations for the air knives with response times of less than 100 milliseconds. Using these models, it was possible to accurately predict the zinc coating across three tracks on both sides of the strip, particularly on the first 100 to 150 metres. This enables early and precise coating transitions for which no thickness values are available from the cold layer measurement. 

Beyond prediction, the analysis showed the potential for dynamic adjustment of safety margins during the strip run based on process stability. This is a sophisticated application of prescriptive analytics, where machine learning not only predicts results, but also directly provides Information and optimises control solutions in real time. 

Your Production Data – the Key to higher added Value
The use case presented here shows how machine learning can be used to achieve specific, value-adding goals in the production of galvanised steel.

With the EMG iCASS® platform, EMG provides production and quality teams with the technological backbone and expertise to effectively utilise their process and quality data – for greater transparency, higher efficiency and sustainable quality assurance.

Whether you want to improve production control, reduce rework or recognise hidden patterns in your data: EMG offers you proven tools and customised support for researching and implementing solutions based on machine learning – combined with many years of experience in classic strip guiding control and quality assurance systems.

To help you get started, EMG offers the first three basic data analyses in steel production or processing free of charge – a risk-free way to evaluate the potential of your data and our EMG iCASS® platform and identify promising applications together with our experts.

Get in touch with us today to take the first step towards intelligent, data-driven improvement of your production process: icass@emg-automation.com 

More about EMG iCASS® under: Process optimisation for the metal industry with AI