Gauge and tail-end loss
Off-gauge head and tail metres are cut and scrapped on every coil. On a tandem mill running a mile of strip, microns of drift are tonnes of downgrade.
Now onboarding design partners for hot-strip and tandem cold mills
Physical AI for steel & flat-metals rolling
Autonomy for the rolling mill.
Steelira runs the loop from schedule to coil: autonomous gauge and shape control, AI strip-surface inspection, TMCP and roll-force optimisation, anneal and coating control, chatter and roll-wear intelligence — on a mill-and-metallurgy twin that hits target gauge, flatness and properties before the pass.
Mill-edge inference under 50 msWrite-back through your Level-2, not around itImmutable audit log per coil
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
Built with steel and flat-metals producers across four continents
NordStrip Steel
Kalyon Metals
Ferrata Group
Aurum Flat Rolled
Meridian Coil
Volkan Çelik
Design-partner results
The numbers the pulpit actually argues about
Measured on design-partner lines in shadow and assist mode against baselines agreed before deployment. Results vary by mill, grade mix and instrumentation.
1.9 ptsPrime-yield uplift on the wedge line, versus a pre-agreed 12-week baseline
38%Reduction in off-gauge head and tail metres per coil
11.4%Reheat and anneal energy reduction at constant throughput
46msMedian mill-edge inference latency, sensor frame to decision
[PLACEHOLDER] Figures reflect design-partner engagements in progress; full methodology available under NDA.
The problem
Rolling is the last black art in a $1.9-trillion industry
A roll gap a hair off leaves the strip off-gauge. The wrong thermomechanical path misses properties on an automotive grade. Scale and slivers downgrade a coil worth six figures. And the people who know how to prevent all three are retiring.
Flatness and shape defects
Crown, wedge, edge-wave and centre-buckle turn into rejects and customer claims long after the coil has left the mill.
Surface downgrade
Scale, scratches, slivers, inclusions and roll marks are caught by inspection systems that flag but never act on the mill.
Property and coating misses
Automotive, appliance and electrical grades fail mechanical or coating spec because the TMCP path drifted three stands upstream.
Roll wear, chatter, cobbles
Thermal crown and third-octave chatter damage rolls, wreck strip and cause the cobbles that cost a shift of production.
The retiring roller
Master rollers and mill metallurgists carry the setup craft in their heads. Nothing in the plant captures it before they leave.
How it works
One closed loop, running at mill speed
Steelira is a system of action, not a dashboard. It perceives the coil, plans the pass, writes the setpoints and proves the result — with a human checkpoint wherever you want one.
- STEP 01
Perceive
Slab, strip, surface, shape, temperature, vibration and drive telemetry are fused at the mill edge into a single coil state, 40–60 times a second.
- STEP 02
Plan
The twin simulates roll-bite mechanics, thermal evolution, flatness and microstructure to pick the schedule, roll and TMCP path that hits gauge, flatness and properties.
- STEP 03
Act
Setpoints are written back through your Level-2 within signed, clamped limits — assisted first, then autonomous on the loops you promote.
- STEP 04
Verify
Every pass is scored against the twin's prediction and the coil's measured result, logged immutably, and fed back as training signal from your engineers' corrections.
The agents
Seven agents under one mill orchestrator
Each agent owns a real mill responsibility and can be bought on its own. Together they close the schedule → roll → inspect → anneal → coat loop.
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.
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.
All seven agents
Yield & Energy, plus the metallurgy-knowledge agent that grounds every recommendation in your grade specs and standards.
The twin
Hit gauge, flatness and properties before the pass
An Omniverse-based mill-and-metallurgy twin simulates roll-bite mechanics, thermal evolution, flatness and microstructure — then auto-optimises roll gap, force, tension and TMCP path for the coil that is actually about to be rolled.
Twin-to-pass auto-optimisation
Before the slab leaves the reheat furnace, the twin has run thousands of candidate schedules for its exact chemistry, width, target gauge and grade window — and returned the one with the highest predicted prime yield inside your safe operating envelope.
10k–100k simulated cases per linecuOpt schedule searchOmniverse physics
Predicted vs. actual
Every pass is scored against the twin. Median gauge prediction error on validated grades: 0.004 mm.
Synthetic rare events
Cosmos and Replicator generate edge-wave, chatter and cobble precursors you cannot afford to produce for real.
Grade-aware
Trained per grade family — automotive high-strength, appliance, electrical steels and aluminium flat-rolled.
Explainable to a metallurgist
Every recommendation cites the coil history, grade spec and standard it came from. Your process engineer can see why the twin moved the third stand, disagree, and have that disagreement become training signal.
Proof
What the people on the pulpit say
Design-partner quotes from active engagements. Company names used with permission.
“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.”
Integrations
Speaks the mill's language on day one
Pre-built connectors to the systems already running your line — read for perception, write for control, with the same audit trail on both.
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
Security
OT-safe by construction
Steelira writes to mill equipment, so security and safety are product requirements, not paperwork.
SOC 2 Type IIISO 27001IEC 62443 alignedGDPRSSO / SAMLData residency
- Segmented OT pathEdge runtime sits in a Purdue Level-2/3 DMZ with signed, rate-limited write-back and hard setpoint clamps.
- Deterministic fallbacksEvery control loop degrades to the mill's existing Level-2 setup on watchdog timeout — the mill never stops because Steelira does.
- Grade-IP isolationRecipes, grade specs and coil histories are tenant-scoped, encrypted at rest with per-tenant keys, and never used to train another producer's models.
- Assurance-grade auditEvery perception, recommendation, approval and actuation is written to an immutable, exportable log keyed to coil ID.
Pricing
Land on one line. Expand across the plant.
Subscription pricing per mill or line, per plant, or across a group — with outcome components tied to prime yield, energy and scrap.
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
Roll the next coil on Steelira
Book a mill assessment. We shadow one line for six weeks, baseline prime yield, energy and scrap, and show the model's gauge, flatness and surface calls against your own results — before anything writes to the mill.