Lighthouse ERP
Met Coke & Calcined Pet Coke Industry
Simple to Use
Easy to Implement
Flexible to Customized Solution
The Metallurgical Coke (Met Coke) industry relies on high-grade met coal to produce coke used in blast furnaces for steel production. As global demand for steel rises, so does the need for high-quality met coke, making it essential for manufacturers to manage production, quality, and inventory with precision.
Similarly, the Calcined Petroleum Coke (CPC) industry plays a vital role in aluminium manufacturing, where CPC is used to produce carbon anodes. The process involves complex operations such as calcination in rotary or shaft kilns, moisture control, and grade-specific handling, all of which demand accurate monitoring and process control.
To handle these critical operations, Lighthouse ERP offers an industry-specific solution with core erp modules like Production Planning, Batch-wise Inventory Management, Quality Control, Plant Maintenance, Finance & Costing, and Sales & Dispatch. With 38+ years of domain expertise, ERP for met coke and calcined pet coke helps coke producers gain real-time visibility, reduce production losses, and meet both domestic and export demands efficiently.
Improper blending results in inconsistent coke reactivity index (CRI), coke strength after reaction (CSR), and reduced anode performance for aluminium smelters develops need of ERP for metals manufacturers.
Directly affects CSR/CRI values, leading to rejection by steel plants and high rework costs. Charge scheduling errors also cause problems in quenching and pushing.
Mismanaged heat curves cause under-calcination (leading to high volatile matter) or over-calcination (causing loss of density), both making the material unfit for anode-grade applications.
Non-uniform porosity and density impact downstream aluminium smelting or blast furnace performance, leading to customer rejections and penalties.
Unexpected shutdowns, poor insulation, energy loss, and safety hazards. Manual maintenance tracking increases downtime and risks.
Manual reconciliation fails to ensure optimal blending or FIFO/FEFO, leading to excess or expired material wastage.
Frequent maintenance, high replacement costs, and unplanned shutdowns. Downtime tracking and spares planning is often not digitized.
ERP for coke and calcined petroleum ensures accurate blending of coal and green pet coke by integrating parameters like moisture, ash, sulfur, and fixed carbon. This maintains uniform CRI and CSR values, reducing product rejection in steel and aluminium applications.
Using advanced ERO software for CR steel coil manufacturing, quality checks are logged at each stage with WIP traceability that links defects to exact batches, shifts, or raw material origins. This is supported through RCA and audit preparation.
The system aligns oven conditions with charge inputs using real-time data, minimizing human error during pushing, quenching, and carbonization. This improves consistency and reduces costly rework cycles.
ERP software for coke helps manage the calcination curve by monitoring kiln temperatures and residence time, preventing under- or over-calcination. This ensures the pet coke meets anode-grade standards with optimal volatile matter and density levels.
With lab testing integrated into batch tracking, met and calcined ERP detects deviations in porosity and bulk density early. This safeguards final product quality and enhances smelter and blast furnace efficiency.
The software monitors kiln refractory wear, insulation, and operating hours to enable preventive maintenance. This reduces unscheduled shutdowns, improves plant safety, and extends equipment life.
ERP for the scrap and recycling industry tracks inventory by yard, lot, and quality index. It enables FIFO/FEFO practices, smart blending decisions, and avoids material expiry or waste due to manual errors.
ERP for metal processing plants captures wear data on conveyor belts, crushers, and stacker-reclaimers, helping schedule timely maintenance. It reduces downtime and optimizes spare part inventory management.
Batch-wise tracking with Lot control, kiln shift logs, and real-time stock visibility. BOM and MRP enable accurate monthly production planning.
Batch-wise quality checks with lab integration ensure real-time testing and automated alerts for quick rejection insights.
Track per-ton production costs with real-time MIS and drilldowns by plant, department, and item. Get accurate stock valuation and division-wise financial visibility.
Capture raw material quality at entry, manage yard-wise stock via screening plant, and track all material movements from gate to yard across various scenarios like rake inward, returns, and scrap.
Track materials batch-wise across blending, calcining, screening, and link them with quality checks, dispatch records, and final sales for full traceability.
Sales and distribution module covers enquiry to delivery with e-invoicing, lot/grade-wise dispatch control, credit checks, and custom pricing terms. Integrates with weighbridge and delivery orders for seamless execution.