Manufacturing · Iron Foundry Management Software

Heat, pattern and test bar tied to every iron casting.

One record carries a casting from order through pattern, core box, charge sheet, heat, pour, test bar, fettling, machining and dispatch, including why parts were rejected. Each casting lot keeps its heat number, pattern and test bar results, so a buyer asking about a crack or a hard spot gets an answer from the file. Planners, the melting bay, the moulding line and the lab share one heat.

Share your requirements

Part list, patterns and grade rules entered from your own drawings and pattern cards
Open orders, scrap and pig iron stock, and balances migrated
Certificate and packing list layouts matched to your customers’ formats

An iron foundry can plan moulds against orders and patterns, then record charge, heat, pouring, test bars and rejection causes within one GullySystem build. Each casting lot keeps its heat number and pattern. Material certificates and the shipping paperwork print from the same record.

Where it breaks today

What goes wrong before the software.

Orders and patterns are matched by memory

A returning customer’s pattern is on a rack, but its mould count and last repair are not written anywhere the planner can see.

Charge sheets are written after the pour

Pig iron, steel scrap, returns and alloy additions get written down only after the shift has finished. Corrections after the spectro reading are lost.

Heat identity disappears at shakeout

A flask carries a chalk mark of the heat. After shakeout the castings fall into one bin, and the chalk mark goes with the flask.

Rejection causes are lumped together

Sand holes, shrinkage, cold shuts and broken cores become one reject count. The foundry cannot see which stage creates the loss.

Core supply holds up the line

Cores are made in a separate shop and arrive late or in the wrong count. The moulders wait, and the day’s pour slips.

Certificates are assembled by hand

Chemistry from the spectro, tensile from the lab and hardness from the bench are copied onto a certificate. A transposed digit reaches the customer.

How it runs

How the work flows through it, step by step.

1
Order and pattern
The order is entered with drawing revision, grade, quantity and pattern. The planner checks the pattern’s condition and core needs.
2
Core and mould plan
Cores are scheduled to arrive before the moulds. Moulds are planned per heat so the ladle is not left half empty.
3
Charge and melt
The charge is weighed by material, the heat is numbered, and the spectro result releases it. Ductile iron records treatment.
4
Pour
Moulds are poured at the recorded temperature. The heat’s moulds and the pattern used are logged.
5
Shakeout and fettle
Castings are shaken out, gates are cut, and rejects are counted by cause. Good castings carry their heat number to the next step.
6
Test, process and ship
Test bar results are entered. Castings go to heat treatment or machining where needed, then are packed with their certificate.

Modules

What is inside.

Every module can be switched on, left out or changed to match how your team already works.

Casting part list

Hold each part with drawing revision, grade, pattern, core boxes and fettling notes, so the floor reads the current data.

Orders and moulding plan

Convert orders into moulds per heat and per pattern, and show the day’s plan against core supply.

Pattern and core box register

Count moulds per pattern, log repairs and storage position, and warn the pattern shop when a limit set by your engineers is reached.

Charge and raw material stock

Count pig iron, steel scrap, returns and alloy additions, and record what each heat consumed.

Heat and spectro record

Number each heat, record the charge, spectro result, treatment and pouring temperature, and release or correct it.

Moulding and pouring log

Record moulds made, pattern used, cores set and moulds poured, so each casting lot names its heat.

Shakeout, fettling and rejections

Count rejects by cause and stage, and see which pattern, line or heat produces them.

Test bar and certificate

Save tensile, hardness and microstructure results to the heat, and print a material certificate once they pass.

Heat treatment and machining routes

Move castings through heat treatment furnaces, machining and outside jobs, counting what goes out and what returns.

Packing, delivery and billing

Print packing lists and delivery notes, raise the invoice, post receipts and follow dues by customer.

Solutions inside

The business modules it is built from.

Each one is also available on its own, or inside a system built for you.

Batch and Serial Tracking
Every heat gets a number carrying its charge, spectro result and treatment, and the castings poured from it keep that number.
Production Planning
Orders become moulds per heat and per pattern, set against the day’s core supply and the ladle capacity.
Fixed Asset Register
Patterns and core boxes are tracked as assets with mould counts, repairs and storage positions, so pattern shop work follows use.
Stock Tracking and Alerts
Pig iron, steel scrap, returns and alloy additions are counted, and each heat draws its charge from named stock.
Quality Control
Tensile, hardness and microstructure results are checked against grade limits, and a failing heat holds its castings.
Job Work Management
Castings sent for heat treatment or machining are listed with quantities out, and returns are booked against the same job.
Bill of Materials
A casting lists its grade, pattern, core boxes and fettling notes, so planners see what each order needs before it is moulded.

Services

How we would put it in.

Setup, data migration, integrations and anything built on top.

Who uses it

One system, each person sees their part.

For owners

See heats poured, yield from charge, rejects by cause, pattern condition and customer balances.

For planners

Match orders to patterns, cores and heats, and watch the cores that have not arrived.

For the melting bay

Weigh charges, enter spectro results and number each heat.

For moulders and fettlers

Record moulds, pours and rejects at the line, and mark castings with the heat.

For the lab and dispatch

Enter test bar results, print certificates and pack against the delivery note.

Reports

The numbers the owner asks for.

Orders by part, pattern and promised date
Heats with charge, chemistry and castings poured
Casting yield from metal charged
Rejections by cause, pattern and line
Test bar results by heat and grade
Pattern moulds counted and repairs due
Machining and heat treatment quantities in and out

Good fit

Who this is built for.

Grey iron foundries making pump bodies, brake drums and manhole frames
Ductile iron foundries with magnesium treatment
Jobbing foundries that cast to customer patterns
Foundries with an in-house core shop and fettling bay
Foundries that send castings out for machining or heat treatment

Honest answer

When it is not the right choice.

A craft or art foundry pouring a few bronze pieces can use a simple job book.
Aluminium pressure die casters will find Aluminium Die Casting Company Management Software closer.

Made to fit

Adapted to your business before it goes live.

You are not handed a login and left to it. The product is set up around your records, your people and the tools you already use.

Your grades and patterns

Grades, chemistry limits and pattern cards come in from the sheets your office already keeps.

Test and release rules

Your metallurgist sets the tensile, hardness and microstructure limits for each grade, and the lab screen compares every result with them.

Certificate format

Material certificates follow the layout your customers expect.

Existing records

Pig iron and scrap stock, the pattern list, open orders and balances are brought in before the plant starts using it.

Works alongside

Barcode and label printers
Email
Spreadsheet import for spectro results
Accounting export

Common questions

Questions owners ask before a demo.

Can heat numbers be linked to castings?

Yes. The pour log names the heat for each mould lot, and the casting lot carries that heat to fettling, machining and dispatch.

How does it treat ductile iron?

The heat record adds magnesium treatment, inoculation and nodularity fields. Test bar results then include the microstructure notes your lab makes.

Can spectro results be imported?

Readings can be keyed in, or taken from the output file of the spectrometer once we have seen its layout. Direct machine reading is separate work.

Does it track patterns?

Yes. Each pattern has moulds made, repair history and location. The pattern shop receives a request when a limit is reached.

How are rejections analysed?

Fettlers and inspectors enter a cause for each reject. Reports group them by pattern, heat and line to show where the loss starts.

Can machined castings be tracked?

A machining route lists each step with quantities in and out. The heat number remains on the lot throughout.

Is there a certificate for each heat?

Yes. A certificate is printed per heat or per shipment from the stored results, in the format agreed with each customer.

What do you need from us to start?

We need your part list, pattern cards, grade rules and open orders. Before any figure is given, we run a demo using a few of your parts.

How does scrap and returns accounting work?

Returned gates, risers and rejects are weighed back and credited to the returns stock. The next charge draws from it by weight.

Can data be exported?

Yes. Heats, test results, rejections and shipments can be written to a file in a layout you choose at the outset.

Wondering what it would cost? Share your requirements and an engineer will come back with a scope.

Industries

Businesses that use this.

Iron foundries

Related products.

Book a demo

See Iron Foundry Management Software with your own data.

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Start with your requirements

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