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Predictive control for hot-dip galvanizing with reduced energy consumption

Purecontrol optimizes the thermal control of galvanizing baths.

Thanks to intelligent and predictive regulation of zinc bath temperatures, our solution ensures more uniform galvanization while reducing energy consumption.

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-10%

average energy consumption

Highest quality

thanks to precise temperature delta control

Advanced monitoring

and alerts for worry-free operation

Reduceenergy consumption

Ensure galvanizing quality

Extend the service life of installations

Prevent anomalies

Purecontrol optimizes the entire thermal control process of galvanizing baths.

The solution anticipates temperature fluctuations in the zinc bath and continuously adjusts setpoints to stabilize the process and reduce energy surges. Result: better-controlled energy consumption and more consistent coating quality.

Deployed on over 500 sites, Purecontrol has already proven its effectiveness.

Improve the performance of your facilities without hardware investment, while keeping your energy consumption under control.

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Emmanuel Caillaud

Maintenance and new construction manager at Prestia SBG

The regulation of the dimmers by Purecontrol allows us to maintain a very high quality of galvanization while reducing our energy consumption by 9% in kWh per kg of material: a significant saving on our monthly energy bill reaching 250k€.

Découvrir l’étude de cas

Intelligent control of galvanizing baths

Optimize your galvanizing with less energy consumption

Hot-dip galvanizing requires strict control of zinc bath temperatures. Poor regulation can affect treatment quality, increase energy consumption, and accelerate equipment wear.

Purecontrol operates at the core of the process.
Our solution continuously controls the power controllers that heat the zinc bath. It stabilizes zinc temperature throughout each cycle phase to ensure optimal conditions without overconsumption.

AI governs the entire system and optimizes multiple levers:

Prediction of material arrival in the zinc bath

Stabilization of power controller output

Reduction of energy use based on plant activity

Precise control of temperature delta

Result: more uniform galvanization, tangible energy savings, and a more sustainable process.

Reduction of
consumptions

Our technology enables optimal energy management. By forecasting the plant’s activity periods, we adjust the operation of the power controllers to reduce energy consumption while keeping the zinc molten and ready for the galvanizing process.

Maximizing the quality of galvanization

Thanks to our power controller management system — based on predicting material arrival in the bath (weight, temperature of the parts) — we ensure an optimal temperature gradient between layers. This guarantees that each part is galvanized with a smooth, uniform finish, free from roughness.

Extending the lifespan
Vats

By stabilizing the power output of the controllers, we prevent overheating and temperature fluctuations that can damage the galvanizing tank. This significantly extends the lifespan of the equipment while maintaining high-quality production.

Real-time supervision and automated prediction.

Track all your KPIs in real time and manage your site with peace of mind. Our system alerts you and anticipates key moments for proactive operations management.

The Purecontrol platform provides advanced predictive insights — you stay in control of the setpoints!

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Continuous optimization of power controllers (setpoints sent every minute) and prediction.

Benefit from multi-objective predictive steering:

Holistic and contextual management

Taking into account all the contextual constraints in the management.

Process prediction

Anticipating the evolution of processes over 24 hours

Energy flexibility

Management adapted to periods of low carbon intensity.

Quality stabilization

Adaptive regulation to maintain quality and compliance without overconsumption.

Taking into account external data

Integration of weather, prices and carbon intensity for refined management.

Reconstitution of virtual sensors

Creation of virtual sensors based on existing data.

Power decomposition

Monitoring the energy profile of equipment without a sub-meter

Predictive maintenance

Early detection of anomalies to anticipate breakdowns.