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Blog post: 14/10/2025 9:37 am

Author: Spark Team

VR SOP Training for Aluminium Smelting & Extrusion

Custom VR to improve potline stability, extrusion quality and EHS performance

From potline operations to billet casting and extrusion presses, aluminium production requires disciplined SOPs to avoid disruptions and defects. Spark designs and builds bespoke VR SOP training that mirrors your electrolytic cells, casthouse and extrusion lines to standardise critical behaviours under pressure.

Pain points we address

• Potline operations: anode effect prevention, bath chemistry control and crust management.
• Casthouse safety: molten metal + water risk, degassing, grain refining and filtration.
• Extrusion quality: die changeovers, temperature control, quench strategy and profile handling.
• Maintenance & EHS: LOTO, refractory checks, crane lifts and fume control.
• Traceability: billet chemistry, die history and profile inspection records.

How our bespoke VR build works

1. SOP & risk capture: potroom controls, casthouse permits and extrusion CTQs.
2. Scenario design: anode effect response, safe skim/transfer, die swaps and quench adjustments.
3. AI avatar coaching: prompts for pre-lift checks, temperature windows and inspection steps.
4. Assessment & analytics: deviation patterns, RFT, incident precursors and retraining cues.
5. Integration: LMS/QMS links, multilingual modules and role paths (ops, maintenance, QA).

Operational outcomes

• Greater potline stability and fewer anode-effect events.
• Improved extrusion consistency with faster die changeovers.
• Reduced incident potential in casthouse and crane operations.
• Stronger audit trails for customers and regulators.

Why Spark

We build to your cells, dies and quality regimen—no generic modules—so learning transfers to potroom, casthouse and press.

Plan a bespoke aluminium VR SOP programme. Contact Spark.

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