Heraeus Electro-Nite introduces a fibre-optic temperature measurement system

In 2025, Heraeus Electro-Nite launched Chameleon Foundry, an automated temperature measurement system based on fibre-optic technology. Drawing on many years of experience in measurement technology, the company offers a wide range of sensors and accessories that enable precise control of metallurgical processes. These include instruments for monitoring temperature, oxygen content, carbon content and other key quality parameters in molten metal.

Iron foundries achieve precise temperature control without disposable sensors

Chameleon Foundry introduces a new approach to measuring the temperature of molten iron. Instead of conventional disposable temperature probes, the system uses a durable fibre-optic cable that enables direct measurement within the melt. It has been specially developed for use in iron foundries, with a focus on precision, reliability and process safety.

Unlike conventional methods, where operators manually insert the probes into ladles or pouring channels, measurements can now be initiated either fully automatically via PLC-controlled signals or manually at the touch of a button via a user interface.

Once activated, the system automatically lowers the fibre-optic probe into the melt, records temperature data and transmits the results in real time. This approach also reduces the risk to operating personnel from extreme heat and splashes of molten metal.

Improved operational efficiency whilst significantly reducing the need for consumables

Compared to conventional measurement methods based on disposable thermocouples, additional maintenance is required, coupled with higher logistics and storage costs. These systems also incur substantial material costs, as the used thermocouples must be disposed of as waste after each measurement. In contrast, Chameleon Foundry’s FIMT (Fibre in Metal Tube) technology is designed to dissolve directly into the melt.

When used at high-frequency or critical measurement points, this approach can significantly reduce operational costs. A single 25-kilogramme coil enables up to 6,000 measurements and replaces several pallets of conventional sensors. This results in lower storage requirements, reduced transport costs and a lower environmental impact.

The elimination of components such as cardboard sleeves also helps to reduce material consumption and waste, contributing to more sustainable foundry processes. Furthermore, fewer parts need to be replaced over time, which reduces maintenance requirements, improves system availability and minimises the risk of unplanned downtime.

Greater workplace safety for operators and technical staff

One of the main advantages of this new technology is the improvement in workplace safety. In industrial environments where workers are exposed to extreme temperatures, radiant heat, molten metal and potential splashes, manual operations can pose significant hazards.

By enabling fully automated immersion measurements based on fibre-optic technology, the system eliminates the need for direct human contact with the melt. This reduces the likelihood of accidents and helps to create safer and better-controlled working conditions.

Higher product quality through optimised process control

Automated control systems enable more consistent and precise measurements, as these are carried out under identical conditions every time. This consistency helps to improve casting quality, reduce energy consumption and achieve target temperatures more reliably. This helps to minimise problems such as overheating, unnecessary energy consumption and the need for rework.

Overall, this leads to more stable production processes and better-optimised energy efficiency, ensuring consistently high product quality in iron casting production.

Heraeus Electro-Nite in focus

Thanks to its many years of experience, Heraeus Electro-Nite is regarded as the world’s leading supplier of industrial measurement solutions for process monitoring and control in foundries, steelworks and the copper and aluminium industries. Its sensors, measuring instruments and systems are used internationally and stand for efficiency, safety and technological innovation.

Thanks to its global network of production sites and local service teams, the company is able to work closely with its customers through training, technical support and reliable delivery capabilities. This structure enables Heraeus Electro-Nite to develop and deliver bespoke solutions tailored to a wide range of industrial production environments.