Lighthouse ERP
Refractories Manufacturing
Simple to Use
Easy to Implement
Flexible to Customized Solution
The global refractories market reached approximately 34.3 billion in 2024 and is projected to grow to around 42.4 billion by 2029. Iron, steel. Cement, glass, and non-ferrous metals industries remain the primary consumers, relying heavily on specialized refractories to protect high temperature equipment.
Refractory manufacturing involves sourcing variable mineral inputs (e.g., alumina, silica, magnesia), formulating heat-resistant mixes shaping intricate custom parts, and firing in precise kiln cycles. Each stage of raw material quality, chemical consistency, shrinkage control, firing profiles, and dispatch packaging requires close monitoring and traceability.
Lighthouse ERP for refractories is purpose built for these domain-specific challenges. Since 1987, Lighthouse has evolved its refractories ERP software to offer full visibility from supply chain and plant operations to quality, logistics, and finance. Whether managing kiln schedules, binder formulations, shape libraries, or project-based dispatches, our manufacturing ERP Software keeps refractories manufacturers agile, compliant, and profitable in today’s demanding market.
Naturally sourced minerals like alumina, magnesia, and silica vary in chemical composition, leading to unpredictable behavior during mixing and sintering. The mix of materials will not be consistent across batches without proper material management.
With thousands of product codes required for custom orders, manual planning leads to tool mismatches and incorrect sequencing during production.
Improper water/binder mix ratios during castable preparation led to setting failures or weak cured structures a risk when not digitally controlled.
Pieces get misplaced between casting, drying, and firing stages, leading to production gaps and delayed dispatches so WIP tracking with ERP becomes important.
Test results for porosity, or cold crushing strength are often logged on paper, making traceability difficult.
Historical shrinkage patterns and mold calibration data from erp software for manufacturers helps maintain shape precision across batches.
Tool Usage and maintenance reports based on usage cycles and wear trends are generated with plant maintenance module of ERP.
ERP for refractories monitors Digital controls over mix ratios improve castable setting performance, reducing product failures.
Real-time dashboards show WIP status per shape, production line, and kiln helping supervisors make faster decisions.
Lab results are auto tagged to batch numbers and dispatch invoices, improving client trust.
Manage the complete sales cycle from enquiry to invoicing with three-level order processing, dispatch-linked, flexible pricing options, and detailed grade-wise dispatch tracking.
Plan production based on sales orders with defined workflows for each refractory type, supporting BOM, MRP, and key process parameters.
Track live operations like pressing, mixing, and sorting for both monolithic and shaped refractories with built-in rejection and rectification handling.
Ensure batch-wise traceability with raw material test reports, integrated lab results, and automated quality checks via PLC & DCS for real-time performance insights.
Track material flows across gate, weighbridge, lab, and yards with lot-wise and godown-level visibility. Manage inter-order and inter-yard transfers for optional material utilization.
Accurate batch-wise costing with real-time tracking of consumption, losses, and recovery variance.
Per-ton cost analyses with mould life tracking, division-wise finance, and 10-level MIS drill-down for complete financial visibility.
Smooth billing for purchase, job work, and freight with real-time financial linkage and cross-division cost efficiency tracking.