In Brief
EBDS Engineering, a company specialized in detection systems for the steel industry wanted to improve the reliability of its monitoring tools in continuous casting.
- Its objective: to replace an opaque detection system with an intelligent, configurable Breakout Prediction System (BPS) that field engineers can easily understand.
Pepps was chosen to design Emerald BPS-TC, a breakout prediction software now recognized for its accuracy and transparency.
The Challenge
Improving Continuous Casting Process Monitoring
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At EBDS, the technical teams relied on breakout detection systems based on powerful algorithms, but their evolution and configuration remained complex.
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The generated alerts were sometimes difficult to interpret and use in the field, especially in the absence of a structured history or configuration options for engineers.
The real challenge ? Bringing greater clarity, control, and anticipation to existing models while maintaining robustness.
Our Mission
Designing a Custom Breakout Prediction Software
To address these challenges, Pepps designed Emerald BPS-TC, a software solution dedicated to predictive monitoring of casting processes. The system continuously analyzes data from fiber optics integrated into the machines and triggers alerts in case of abnormal behavior. It is built on a 100% transparent architecture, developed in close collaboration with the client’s engineers.
Key Features of the Emerald Supervision System
- An interface designed for field engineers, with clear and straightforward visualization.
- Integration of fiber optic sensors for high-frequency data collection.
- Customizable alert rules and detection algorithms.
- Long-term data storage for sequential review and historical analysis.
- Open software architecture, with no black box, ensuring full transparency of calculations.
- Reproducibility and reliability of results in demanding industrial environments.
The software provides BDS with a reliable industrial prediction tool. This makes it possible to better control casting quality and secure the entire process.
Business Applications & SoftwareThe Results
Impact of the Predictive System on Industrial Performance
Significant Reduction in Casting Accidents
Thanks to early anomaly detection, teams can intervene before critical breakouts occur.
Increased Reliability of the Production Process
The platform continuously analyzes data and immediately raises alerts in case of deviations, helping to stabilize overall performance.
Fewer Unplanned Downtimes, Higher Productivity
Unplanned interruptions are significantly reduced, while machine uptime increases.
Engineer Autonomy in Configuration
Users can adjust thresholds, triggering rules, and algorithms without relying on developers.
Why Choose Pepps for Your Industrial Predictive Maintenance Projects
Pepps designs solutions for heavy industries, integrating technical, safety, and field-use constraints.
We analyze real-time sensor data streams and build predictive analytics engines tailored to production realities.
Our tools are designed to be used directly by engineers, with clear logic, no black boxes, and no unnecessary layers.
The platforms developed allow users to configure their own thresholds, alert rules, and algorithms.
Every system decision is explainable, documented, and recorded. It provides a reliable foundation for quality audits and decision-making.
From design to production, Pepps supports its clients through every phase of the project.
Want to secure your industrial processes with an intelligent prediction solution?
The Emerald BPS-TC project illustrates Pepps’ ability to create predictive maintenance and supervision systems tailored to critical environments.
If you want to make your production lines more reliable, anticipate incidents, or strengthen the autonomy of your technical teams, let’s talk.
Contact Pepps to develop your predictive supervision system.
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