Loic Fracheboud is an Artificial Intelligence and Embedded Systems Engineer with deep expertise in the aluminium production sector. With hands-on experience working alongside operators and process managers, he understands the industrial environment from the ground up. Leveraging his dual academic background, Loic develops cutting-edge solutions that merge AI with embedded systems to drive automation, enhance reliability and support smart manufacturing across the value chain.

In the e-Magazine "Advanced Industrial Technologies in the ALuminium Industry (Part II)", Loic Fracheboud discusses how integrated systems like the GLA and GLS are advancing aluminium casting through Industry 4.0 technologies, supporting real-time monitoring, process optimisation and rapid maintenance in high-throughput environments.

AL Circle: As the aluminium industry increasingly focuses on process optimisation, digitalisation, and sustainability, how does the GAP GLS system integrate with modern casting lines in terms of automation, temperature monitoring, and energy efficient operation? Are there developments in the pipeline that address evolving demands in smart smelting and Industry 4.0 environments?

Loic Fracheboud: Our latest-generation sensor builds on over 15 years of proven reliability in aluminium casting operations. This new 4.0 version introduces advanced communication capabilities, real-time monitoring, and comprehensive data reporting, including sensor health and process-specific information for each ingot. While our focus remains on casting, we collaborate with trusted partners to meet upstream smelting requirements when needed. The data produced integrates seamlessly into SCADA systems, supporting smart factory environments and aligning with the broader goals of Industry 4.0.

AL Circle: Integrating step motors, position sensors, and emergency-stop logic via external control boards strongly emphasises automation and safety. How does the GLA align with the industry’s shift towards Industry 4.0 and smart aluminium foundries?

Loic Fracheboud: The GLA’s architecture supports industry needs for automation and safety. Although the current version is already optimised for its role, a future iteration will include enhanced data collection for condition monitoring and process optimisation. Nevertheless, our approach remains pragmatic: the actuator needs only as much connectivity as is truly beneficial, ultimately responding to predefined commands within a streamlined control environment.

AL Circle: The GLA’s quick interchangeability—less than five minutes— is impressive. How important is this feature for maintenance and operational efficiency in high-throughput aluminium casting lines? 

Loic Fracheboud: Like the GLS, the GLA is designed for rapid replacement, ensuring that equipment changes can be made in under five minutes. This dramatically reduces production downtime and contributes to smoother operations in high-throughput casting lines. It is important to note that both equipment units are designed to be robust and require minimal maintenance or adjustments, supporting continuous operation in demanding industrial environments.

AL Circle: The GLA works in tandem with the GLS (GAP Level Sensor) to optimise metal level regulation. Can you share more about how this system integration enhances performance and what feedback you’ve received from aluminium producers using this setup? 

Loic Fracheboud: The combined use of the GLA and GLS enables a clear separation between measurement and actuation, which improves signal integrity and simplifies maintenance. This separation also eases integration into casting launders, especially in retrofit installations where space is limited. Feedback from aluminium producers has been highly positive, with clients appreciating both the operational flexibility and cost efficiency gained from interchangeable components and modular system architecture.

To explore the full interview and gain deeper insights into the global aluminium casting technology and equipment market, click here.