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GullySystem
Industry category · Casting & Foundry

Tie each heat, pour and casting to its pattern, test result and customer order, from melt to dispatch.

Iron and steel foundries, die casting shops, investment casters and sand casting plants all pour molten metal into a mould and check what comes out. Melts, patterns, dies, inspection results and customer orders are kept together in one traceable record, so a casting can be followed back to its heat.

At a glance

Casting trades share a hot, heavy sequence. Metal is melted to a chemistry, poured into a mould, cooled, knocked out, fettled and inspected before it is released against a customer order. Iron and steel foundries pour into sand moulds. Investment casting companies build wax patterns and ceramic shells. Aluminium die casting and gravity die casting companies fill steel dies, with pressure or by gravity alone, and trim the flash before the part is checked.

The record that matters most is the heat. A furnace charge has a chemistry, a pouring temperature and a list of castings poured from it, with the operator and shift noted. Spectrometer readings, tensile bars, hardness checks and radiography reports all belong to that heat, so when a casting is questioned later the heat number is the way back.

Tooling is the second thread. Sand foundries hold wooden or metal patterns and core boxes, and die casters hold dies with shot counts and repair histories. Foundry component manufacturers often machine what they cast, so the part has to carry its identity from the pour to the finished dimension.

7 trades in this group
The trades

Software for each kind of casting & Foundry business.

Iron foundries

Iron foundries melt grey or ductile iron, pour it into sand moulds, shake out, fettle and often machine the casting. Foundry software holds the heat, charge, pouring temperature, pattern, test bar and rejection cause against each casting, with the customer’s drawing beside them.

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Steel foundries

A steel foundry sells castings, but the customer also buys the paperwork that proves what was poured. The software ties each casting to its heat number, ladle analysis, normalising charge and magnetic particle result. Material test certificates are drawn from those records, so nothing is retyped.

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Sand casting foundries

A sand foundry makes tonnes of castings from sand that changes by the hour. The sand casting foundry software keeps the sand test, the melt analysis and the pour next to the casting that came out. Rejections are counted by cause, pattern and shift.

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Investment casting companies

Lost wax casting passes through a dozen small stages, and a part can be lost at any of them. The investment casting software tracks wax dies, patterns, trees, shell build, dewax, pour and finishing against the customer’s order. Inspection results stay with the part number.

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Aluminium die casting companies

Aluminium die casters melt alloy, inject it into steel dies, trim the shot and machine the casting. Die casting software holds the alloy lot and melt check, die shot counts, trim press yield, porosity findings and leak test results against every casting number.

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Gravity die casting companies

Gravity die casting companies pour molten aluminium or brass into reusable steel dies, with no pressure beyond the weight of the metal. The gravity die casting company software holds each part specification, the melt and alloy lots, the dies and cores, the pour records and the leak and X-ray tests. Orders are planned by die and machine, and finished castings move on to machining.

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Foundry component manufacturers

A casting is judged on dimensions, chemistry and soundness, and this software holds all three against the pour that made it. Pattern plates, core boxes, spectrometer readings, fettling counts and machining routes sit on one job. When a customer returns a gearbox housing, you find the heat, the mould and the shift.

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What they share

Where these businesses lose time and money.

Heat records are kept in a logbook

Charge materials, spectrometer readings and pour temperatures are written by hand at the furnace. Linking a casting to its heat means turning pages. Complaints arrive months later. Then the foundry searches several books, with no certainty that the heat it finds is the right one.

Patterns and dies have no shared history

Pattern wear, core box repairs and die shot counts are known to the moulder or the die setter. Planners book a tool without knowing its condition. Planners book worn tools by mistake.

Defects are found late and logged loosely

Porosity, shrinkage, cold shuts and inclusions are caught at fettling or after machining. The cause is rarely written down against the heat or the tool. Scrap is counted at the end of the line, so the foundry sees how many castings failed but not which stage, which tool or which melt was behind it.

Test certificates are assembled by hand

Chemistry, mechanical results and radiography or dye penetrant reports are gathered from separate sheets for each customer. One missing page holds up the dispatch.

Yield and melt cost are estimated

Gating, risers, returns and scrap change what a casting really costs. Quotes use a rule of thumb, so repeat jobs earn different margins. Because the real yield is unmeasured, a repeat order for the same casting can be priced differently by two people on the same day.

What the software does

What we build across casting & Foundry.

Open a record for every heat

Log the charge, chemistry, pouring temperature and furnace, then link each pour to the castings made from it and to the tests run on its sample. Nothing is poured without a heat number.

Keep a history for each pattern and die

Hold shot counts, wax or core box condition, repairs, storage bay and customer ownership against each tool, so a worn one is flagged before it is scheduled. Planners see which tools are near their limit when they build the schedule, and not after a run has already been started on a worn one.

Follow the casting through fettling and machining

Track each lot from knockout to shot blasting, heat treatment, machining and final inspection, with the stage and the operator recorded at every step. A lot never loses its heat.

Record defects against their cause

Enter the defect type, quantity and location on the casting, and link it to the heat, the mould or the die. Patterns across jobs then become visible. Over several jobs the same cause begins to repeat, and the foundry can act on a melt practice or a tool rather than on a single batch.

Build certificates from recorded data

Assemble chemistry, mechanical and non-destructive test results into a certificate for each order, with the heat number and drawing revision printed on it. Nothing is retyped.

Cost each job from its real yield

Compare poured weight with shipped weight and measure scrap and remelt, so quotes and margins use the yield the foundry actually achieves. The comparison covers risers, gates, returns and fettling loss, so a quote reflects what the shop really pours and ships for that casting.

Common questions

Questions casting & Foundry businesses ask.

Does one product serve every kind of foundry?

No. Sand, investment, die casting and iron or steel foundries keep different records, so each trade has its own product. Mixed plants are scoped during implementation.

Will it take readings from our spectrometer?

Not on its own. A link is scoped per instrument once the model is known, and until then readings are entered or imported against the heat.

Can it show which castings came from a given heat?

Yes. Each pour is linked to its heat. Each casting lot is linked to its pour. A heat number leads to every casting, test and customer order connected to it, which makes a recall or a complaint much easier to answer. It takes one search.

Will it certify our castings to a standard?

No. It holds the test results and produces the certificate layout the customer asks for, while compliance with a standard stays between you, your customer and the assessing body. The software keeps the evidence together.

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