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Blog post: 18/11/2025 1:53 pm

Author: Spark Team

VR SOP Training for Aluminium Smelting, Casting & Rolling

Standardise critical steps from potroom to coil

Aluminium production spans high-energy cells, molten metal handling and precision rolling. Spark builds bespoke VR training that mirrors your anode changes, tapping/transfer, furnace/degassing, DC casting and hot/cold mills—so teams learn safely.

Common pain points

• Potroom: anode effects, alumina feed and bath parameters.
• Metal handling: skimming, fluxes/degassing and inclusion control.
• DC casting: water flow, speed, butt curl and crack response.
• Mills: gauge/flatness control, work roll management and coil quality.
• Safety: molten metal, water/metal explosions and crane moves.

Our build approach

1. Capture SOPs & CTQs: practice sheets, casting recipes and QC limits.
2. Create scenarios: anode change, tap/transfer, cast start/stop, mill set-up and upset recovery.
3. Coach in VR: prompts tied to your HMIs and checklists.
4. Assess: RFT, defect trends and safety behaviours.

Benefits

• Safer molten metal operations.
• Cleaner casts and more stable coil quality.
• Stronger compliance evidence for audits.

Why Spark

We train your exact practice—no generic courses—so skills transfer to the floor.

Ready to scope an aluminium VR SOP programme? Contact Spark.

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