Steel Plants Reduce Waste by 20% Using Explainable AI from Fero Labs

Client Overview

Fero Labs is a U.S.-based AI software company focused on industrial optimization. Its explainable AI platform is used by steel and chemical manufacturers across Europe and North America.

Challenges

Manufacturers often overuse raw materials to avoid defects, increasing costs and waste.

• Lack of real-time visibility into material efficiency
• Overcompensation in formulations to stay within spec
• High energy and resource consumption

Solution

Steel producers deployed AI for process optimization using Fero Labs' industrial AI engine.

• Modeled thousands of production scenarios for predictive control
• Provided live recommendations to operators based on conditions
• Highlighted causes of inefficiency in plain language

Business Impact

AI helped reduce waste and increase ROI on raw materials.

• Cut raw material waste by up to 20%
• Maintained product strength and compliance standards
• Reduced unnecessary alloy use, saving millions in input costs

Client Testimonials

“Fero’s explainable AI helps our engineers make smarter, cost-effective decisions on the line.” - Gianni De Luca, Optimization Lead, European Steel Group

“We’re finally using AI that shows its work. No more black box.” - Mariana Costa, Process Analyst, Midwest Steelworks