From 6–9 October 2025, the European steel community will gather in Verona, Italy, for the European Steel Technology and Application Days (ESTAD). The event is one of the largest conferences in the field of steel production and processing, offering a unique forum for technical exchange and industry networking. EMG Automation GmbH will contribute to this international platform with a poster presentation showcasing EMG iCASS®, a modular, AI-driven platform designed to optimise continuous galvanizing processes.
For further information about ESTAD, please visit our website: ESTAD 2025
The Challenge: Balancing Quality and Efficiency in Hot-Dip Galvanising
Hot-dip galvanising remains a crucial process step in modern steel production, ensuring corrosion protection and durability. However, achieving precise zinc coating thickness while minimising material consumption is a persistent challenge. Traditional control approaches often rely on delayed measurements, leading to reactive adjustments and inefficiencies – particularly during strip transitions, when material grades or coating targets change. This results in increased zinc consumption, reduced process stability, and higher scrap rates.
In this context, EMG has developed the EMG iCASS® (intelligent Control and Analytical Software Solutions) software platform, a module-based environment that combines machine learning, predictive analytics, and real-time control to provide a proactive alternative to traditional process optimisation and control methods.
EMG iCASS®: Modular AI for Real-Time Optimisation
The EMG iCASS® platform is structured as a set of specialised modules that can be implemented individually or as part of an integrated control solution.
Each module addresses a specific optimisation challenge in continuous galvanising lines (CGLs):
- Virtual Hot Measurement Module: Predicts zinc coating thickness immediately after strip transitions, reducing dependency on conventional hot measurement systems and avoiding the scrap associated with delayed cold measurement results.
- Safety Margin Adjustment Module: Dynamically adjusts zinc coating safety margins to avoid undercoating while minimising unnecessary overcoating, leading to significant material savings.
- Nozzle Position Optimisation Module: Works in combination with EMG eMASS® strip stabilisation to eliminate wedge-shaped coatings and improve transverse homogeneity.
- Real-Time Coating Control Module: Provides closed-loop control of the galvanising process by adjusting parameters such as air knife pressure based on predictive models, ensuring consistent quality and efficiency.
Industrial trials confirm that EMG iCASS® enhances process stability, reduces zinc consumption, and improves overall product consistency. By leveraging both historical and live data, the system adapts dynamically to changing production conditions, making it a future-proof solution for intelligent steel production.
Why ESTAD 2025?
ESTAD is the leading European conference on metallurgical process technology. The 2025 edition in Verona will bring together experts, researchers, and practitioners from across the steel value chain. Key topics include digitalisation, sustainability, and innovations in steel production – areas where EMG iCASS® provides tangible benefits. With its modular approach, the platform aligns directly with the industry’s drive towards efficiency, resource savings, and smart manufacturing.
For EMG, contributing to ESTAD is not only an opportunity to share technological innovations but also to engage with industry stakeholders on the future of galvanising. The poster session offers a dedicated space for in-depth discussions, allowing participants to explore practical use cases and potential applications of EMG iCASS® in their own operations.
Meet us in Verona & get involved at the ESTAD poster session
We warmly invite all ESTAD participants to visit the EMG poster presentation on “Smarter Galvanizing through Zinc Coating Optimization with EMG iCASS®”.
Our expert Mark Kreso, Senior Director Technology at EMG, will be on-site to explain and present the concept, discuss industrial trial results, and exchange ideas on how data-driven process optimisation can be applied in different production environments.
ESTAD 2025 – 6-9 OCTOBER 2025
Poster Session: Smarter Galvanising through Zinc Coating Optimisation with EMG iCASS®
Your contact: Mark Kreso, Senior Director Technology, EMG Automation GmbH
Date and time: October 7th, 19:46 at Foyer (Palaexpo Veronafiere)
Don’t miss the opportunity to discover how EMG iCASS® is shaping the future of galvanising – smarter, more efficient, and more sustainable.
More info:
Web: Process optimisation for the metal industry with AI
ESTAD Timetable: 7th European Steel Technology and Application Days - ESTAD 2025 (6-9. Oktober 2025)