Roll & Gauge agent
Holds exit gauge to microns by trimming roll gap, roll force, bending, shifting and inter-stand tension pass by pass — including the head and tail ends where prime yield is lost.
Products
Modules that add up to a mill
Buy one line module and prove it. Add the next when the first has paid for itself. The twin ties them together into a plant that plans, rolls and finishes as one system.
Land on one moduleExpand across the plantOne registry per group
exit gauge1.982 mm
flatness I-unit3.1 IU
F5 roll force18.4 MN
interstand tension9.6 MPa
chatter margin0.24 · safe
anneal energy-11.4%
pass 6/7autonomy: assisted-writetwin delta 0.004 mmaudit id 7f31c
Modules in production across design-partner plants
NordStrip Steel
Kalyon Metals
Ferrata Group
Aurum Flat Rolled
Meridian Coil
Volkan Çelik
Modules
Seven products, one runtime
Every module ships with its own validation harness, its own promotion gates and its own ROI metric.
Surface & Shape agent
Fuses high-speed strip-surface vision with shape-meter and thermal data to detect and predict scale, scratches, slivers, inclusions, roll marks, edge-wave and centre-buckle.
Schedule & Flow agent
Optimises the rolling schedule, reduction split and thermomechanical path so the coil hits target properties in fewer passes, with campaign and roll-change planning on cuOpt.
Temper & Coat agent
Controls annealing, temper/skin-pass, pickling and coating weight so mechanical properties and coating spec land inside the window without over-coating.
Roll & Chatter agent
Predicts roll wear, thermal crown and third-octave chatter precursors to schedule roll changes early and steer the mill away from instability and cobbles.
Robot & Handling agent
Drives robotic coil handling, strapping, sampling and lab logistics on Isaac-based cells so sample-to-result time stops gating the next campaign.
Yield & Energy agent
Optimises prime yield, scrap and cobble risk against reheat and anneal energy — the two levers that decide margin and CO₂ on the same coil.
The twin
Mill-and-metallurgy digital twin
The product that makes the others worth more: an Omniverse-based simulation of roll-bite mechanics, thermal evolution, flatness and microstructure, tuned to your mill from your own coil history.
Hit gauge, flatness and properties before the pass
Give the twin a chemistry, a width, a target gauge and a grade window and it returns the schedule, roll and TMCP path with the highest predicted prime yield inside your safe envelope — validated against thousands of simulated cases and every coil your mill has actually rolled.
anchor: #twinΔ gauge 0.004 mm mediancuOpt search
Calibrated to your mill
Stand stiffness, thermal crown behaviour and lubrication response are fitted from your history, not a textbook.
Property prediction
Yield, tensile and elongation predicted per coil for the grades you actually sell.
What-if for engineers
Try a schedule change against the twin before you try it against a customer's coil.
Synthetic rare events
Cosmos and Omniverse Replicator generate edge-wave, chatter, cobble precursor and coating-fault scenarios by the million so the models see failures your mill has been careful never to produce.
Consoles
Where people meet the autonomy
Three surfaces, each built for one job.
Pulpit console
A single screen for the operator and rolling engineer: live coil state, the agent's next proposed move, the twin's prediction and one button to approve, adjust or reject. Designed to be read at a glance from two metres away in a hot mill.
- Approve or correctEvery correction is captured as training signal, attributed to the engineer who made it.
- Autonomy visibleThe current autonomy level and envelope for each loop are always on screen.
exit gauge1.982 mm
flatness I-unit3.1 IU
F5 roll force18.4 MN
interstand tension9.6 MPa
chatter margin0.24 · safe
anneal energy-11.4%
pass 6/7autonomy: assisted-writetwin delta 0.004 mmaudit id 7f31c
Quality & metallurgy console
Per-coil predicted and measured gauge, flatness, surface and properties, with defect maps positioned along coil length and a full decision trail exportable for any claim investigation.
- Claim-ready exportThe whole reasoning chain for a coil, in one signed PDF or JSON bundle.
- Grade analyticsProperty distribution by grade family, mill and campaign.
gauge 1.982 mm target 1.980 ±0.015 PRIME
flatness 3.1 IU limit 8.0 IU PRIME
surface 0 defects scanned 100% length PRIME
YS 347 MPa window 320–400 PASS
coating 78 g/m² spec 75 min PASS
audit 7f31c · 214 decisions logged
Plant & group analytics
Prime yield, energy intensity, scrap, cobble rate and roll consumption per line, per shift, per grade — benchmarked across your own sites, and against anonymised industry cohorts on Enterprise tiers.
- Cohort benchmarksSee where a line sits against comparable mills without exposing anyone's data.
- Shift and campaign viewsFind the pattern behind the bad Tuesday.
exit gauge1.982 mm
flatness I-unit3.1 IU
F5 roll force18.4 MN
interstand tension9.6 MPa
chatter margin0.24 · safe
anneal energy-11.4%
pass 6/7autonomy: assisted-writetwin delta 0.004 mmaudit id 7f31c
Module map
What each module needs and returns
A planning view for your OT and capex conversations.
| Module | Primary signals | Writes to | Headline metric |
|---|---|---|---|
| Roll & Gauge | Gauge, roll force, tension, speed | Level-2 gap / bending / tension | Off-gauge metres per coil |
| Surface & Shape | Line-scan cameras, shape-meter, pyrometers | Bending, shifting, cooling | Surface downgrade rate |
| Schedule & Flow | Order book, chemistry, slab data | Level-2 schedule / setup | Passes per coil, property first-pass yield |
| Temper & Coat | Furnace zones, elongation, coating weight | Line speed, zone setpoints, air knives | Coating over-spend, property misses |
| Roll & Chatter | Vibration, roll force, thermal model | Roll-change plan, speed limits | Cobbles, roll consumption |
| Robot & Handling | Cell vision, coil tracking | Robot cell controllers | Sample-to-result time |
| Yield & Energy | All of the above, plus furnace fuel | Furnace dispatch, schedule | Energy per tonne, prime yield |
Adoption
The expansion path most plants take
Land narrow, expand relentlessly — with each step justified by the last.
- STEP 01
Module one
Gauge/shape control or surface sensing on the highest-value line, in shadow then assist.
- STEP 02
Module two
The adjacent loss on the same line — usually chatter and roll health, or coating weight.
- STEP 03
The twin
Turned on once two modules are in assist, so planning and control share one physics model.
- STEP 04
Plant tier
All modules, all lines, one objective function, graduated autonomy line by line.
Proof
Modules in the field
“We ran Steelira in shadow for eight weeks on the tandem mill. It called eleven of the twelve off-gauge tail events before our AGC reacted. That was the moment the argument ended.”
“Our best roller retires in two years. Steelira is the first system that captured how he sets up a hard automotive grade — and then explained why, with the coil history to back it.”
“Prime yield moved 1.7 points on the galvanizing line and reheat gas fell double digits. Nothing else we bought this decade did both.”
Interoperability
Every module speaks to your systems of record
Modules read from and write to the same connector layer, so adding the second is an afternoon, not a project.
Level-2 & control
- Primetals Level-2
- SMS X-Pact
- Danieli Automation
- TMEIC mill drives
- ABB Ability
- Siemens SIMATIC / PCS 7
Gauge, shape & surface
- IMS X-ray gauges
- Vollmer thickness
- Shape-meter rolls
- ISRA Vision surface
- Parsytec inspection
- Thermal line scanners
Plant systems
- Level-3 MES / QMS
- SAP PP-PI
- OSIsoft PI / AVEVA
- OPC UA & Classic
- Historians (IP.21, Canary)
- CMMS / EAM
Packaging
Modules map cleanly to plans
One module on one line is the Line plan. Every module on every line is the Plant plan. Multi-site is Enterprise.
Line
per mill or line, per month
Producers validating ROI on the wedge workflow.
- Gauge/shape control or strip-surface defect sensing for one mill or line
- Mill edge runtime on certified GPU hardware
- Level-2 / AGC / shape-meter / inspection connectors
- Review console for rolling & process engineers
- Assurance-grade audit log and shadow-mode baselining
- Standard support, 8×5, next-business-day response
Plant
Most popularper plant, per month
Scaling plants adopting the full perceive-decide-act loop.
- Everything in Line, across every mill and finishing line on site
- Roll & gauge + surface & shape + schedule/TMCP agents
- Anneal, temper and coating control + roll-wear & chatter intelligence
- Robotic coil handling and lab-logistics orchestration
- Mill-and-metallurgy digital twin with hit-gauge-before-pass
- Graduated autonomy with human-in-the-loop checkpoints
- 24×7 support, named mill success engineer
Enterprise
typical land $900k–$10M ACV
Steel and metals groups standardizing on Steelira.
- Multi-site rollout with a managed mill edge fleet
- Custom grade, mill and property models per plant
- On-prem or air-gapped deployment options
- SSO/SAML, SCIM, RBAC and data-residency controls
- Contractual uptime and control-latency SLAs
- Outcome-based commercial components
- Executive business reviews and roadmap influence
Pick the module that pays back first
We will rank every module against your line's measured losses and tell you which one to buy — including the case for buying none of them yet.