By partnering with Monitizer, Lianhuashan Foundry brings every aspect of production into one clear view—unlocking greater efficiency, reducing energy costs, improving quality and increasing uptime. This data-driven approach empowers the team to lead the way in smart, sustainable manufacturing. 

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With Monitizer and DISA’s foundry experts behind it, Monitizer | DISCOVER IIoT solution is driving real results at Huludao Lianhuashan Foundry Co., Ltd—delivering higher casting quality while cutting energy costs and downtime. 

Monitizer | DISCOVER brings all production data together into one clear, intuitive dashboard. Designed by foundry specialists, this proven IIoT platform gives teams a single view of every site, line and machine—empowering smarter, faster decisions and driving sustainable growth. 

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“From melting, moulding, and sand mixing to pouring, you need to digitally monitor the whole process,” says Haotian Ren, Managing Director of Lianhuashan. “Monitizer | DISCOVER is a very effective way to collect and display real-time data from our key on-site equipment. It gives us the information we need to improve casting quality, production efficiency and equipment uptime.”

Digital tools made for foundries

Lianhuashan is based in Huludao, Liaoning Province, China, and provides 15,000 tons of high-quality, grey and ductile iron castings annually to leading domestic and global brands. With DISA vertical and horizontal moulding lines, more than 150 CNC machine tools, and a well-equipped laboratory, the foundry constantly adds the latest automated equipment to its facility. 

Before Monitizer, Lianhuashan’s team spent hours on manual data entry and stored its data in separate silos, so it had no overall view of its production. Embracing digital solutions would help it track and improve every part of its process. 

“In today's foundry industry, digital systems are essential to improve casting performance and profitability,” says Haotian. “We chose Monitizer after researching and comparing many digital solutions. Because it was developed for foundries, Monitizer has significant advantages for our moulding lines and sand processing equipment.”

Lianhuashan’s main digital goals are to increase casting quality and promote efficient production. “We wanted real-time data for every part of our process,” says Haotian. “That would help us improve efficiency and trace quality parameters to steadily improve product quality.”

Rapid roll-out, trusted team

“DISA are our long-term partners, and we trust them and their equipment,” says Haotian. “We knew their deep foundry experience would help us improve our digital management capabilities, too. It was the right decision. From project planning through implementation and service, we have been very satisfied with both Monitizer and DISA’s professionalism and support.”

After rapidly connecting key equipment, Lianhuashan views data from melting, moulding, sand mixing, and sand testing. The data is simultaneously saved for future reporting and analysis. 

“Establishing a central, cloud-hosted foundry database was an important first step to support our future production,” says Haotian. “Every day, Monitizer | DISCOVER helps us easily grasp key information such as the operational status of sand processing and the reasons for equipment shutdown.”

Cut energy costs by shifting to off-peak electricity

Whether viewing large screens on the factory floor or via remote Internet access, the entire factory knows exactly what’s happening on the line.

“No matter where managers are, they can check equipment operation and sand mixing parameters in real time or really understand what is going on inside a moulding line,” says Haotian. “DISCOVER has removed data silos and helps us prevent errors, predict production line efficiency and conduct scientific evaluations.”

Lianhuashan used DISCOVER to analyse equipment operating times and energy consumption across the working day. By shifting as much production as possible to off-peak times when electricity is cheaper, it reduced energy costs dramatically.

“We can clearly see each machine’s electricity consumption and operation time, so we can adjust our schedule to avoid peak electricity prices,” says Haotian. “We already know how to solve many production problems quickly using DISCOVER and our teams share these solutions in weekly online meetings.”

Business growth, powered by digital

“DISCOVER has given us deep insight into our factory's production and helps us promote our business expansion,” says Haotian. “Our customers know we have excellent process control and high-quality standards. Seeing our digital management tools during on-site visits further increases the confidence they have in us.”

Lianhuashan currently manually inputs testing, melting and pouring data, then exports it to DISCOVER. Working with Monitizer, the foundry’s next steps will be to automate data collection for melting and pouring, target further energy cost reductions and set up more fault alarms—simple to configure in DISCOVER.

“The digital system acts like our eyes, allowing us to see more completely and accurately into places that are usually difficult to reach,” says Haotian. “The Monitizer team always listens carefully to our needs, responds quickly and consistently follows up. Through extending and optimising the Monitizer system, we will bring even more value to the enterprise.”

Note: The image used in this article is generated with an AI tool and does not depict any real-time moment.

Note: This article has been issued by Lianhuashan Foundry and has been published by AL Circle with its original information without any modifications or edits to the core subject/data.

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