The Gap Isn't In
Your Furnace.
It's In Your Software.
Eliminate manual logging and fragmented data silos. Kernopy Forge consolidates your entire thermal processing operation into a single, deterministic intelligence layer.
1,048
523
820
THE PROBLEM
MODERN METALLURGY.
LEGACY OPERATIONS.
Your equipment is capable. Your data exists. The infrastructure to act on it doesn't — until now. Most plants lose efficiency not from hardware failures, but from disconnected software layers.
Failures Found The Next Morning
Critical deviations go undetected until the next shift reviews paper logs. By then, the batch is already ruined.
Inconsistent Audit Records
Handwritten entries, mismatched timestamps, and missing signatures make compliance reviews a recurring headache.
Recipes In A Local Machine
Process recipes live on a single operator's PC. No versioning, no backup, no way to trace what changed and when.
No Remote Visibility
Plant managers and engineers have zero real-time insight into what is happening on the furnace floor when off-site.
WHAT KERNOPY DOES
BUILT FOR THE
FURNACE FLOOR
Purpose-built modules that address every critical layer of your thermal processing operation — from live monitoring to compliance and alerting.
Real-Time Process Monitoring
Live dashboards connected directly to your furnaces. Track temperatures, cycle times, and deviations the moment they happen — not the morning after.
Predictive Maintenance
Detect equipment degradation before failure occurs. AI-driven anomaly detection on thermal signatures, vibration, and cycle patterns predicts issues days in advance.
Recipe Management
Centralized, version-controlled process recipes with full traceability. Know exactly what changed, who changed it, and when — across every furnace.
Rules Engine & Alerting
Define custom rules on any process variable. Get instant alerts via SMS, email, or webhook when thresholds are breached — before damage is done.
ARCHITECTURE
EVERY DATA POINT FOLLOWS A
DETERMINISTIC PATH.
From sensor to screen, every signal travels through a defined, auditable pipeline. No black boxes, no silent data loss, no ambiguity in how a value reached the dashboard.
Field Devices
Sensors, PLCs, thermocouples, and industrial controllers on the furnace floor. The raw source of every data point in the system.
Edge Runtime
Protocol gateways and edge compute nodes that translate, normalize, and buffer data before it leaves the plant network.
IoT Core
Centralized device registry, time-series historian, and integration APIs. The backbone that connects field data to every application layer.
CONNECTS TO WHAT
YOU ALREADY HAVE
Standard industrial protocols. No gateway licenses to purchase. No PLC programming. No disruption to your production line.
Kernopy never touches your safety controls.
Modbus TCP/RTU
Industry standard PLC connectivity.
OPC-UA
Connectivity to legacy instruments.
MQTT
Lightweight edge-to-cloud messaging.
REST APIs
Proprietary integrations on request.
BUILT FOR OPERATIONS. LIKE YOURS.
WHO WE WORK WITH
OEM, EQUIPMENT MANUFACTURERS
Furnace OEMs & Equipment Builders
Embed live telemetry and remote diagnostics into your product — without building it from scratch.
COMMERCIAL, HEAT TREATMENT
Commercial Heat Treatment Providers
Multi-furnace visibility, automated cycle reports, and deviation alerts across every shift.
IN-HOUSE, CAPTIVE OPERATIONS
Captive Furnace Operators
On-prem deployment, Modbus/OPC-UA connectivity, and recipe control — no PLC replacement needed.
AEROSPACE, REGULATED INDUSTRIES
Aerospace & High-Stakes Manufacturers
Air-gapped deployment, structured reporting, and batch-level traceability for operations where deviation isn't an option.
BUILT FOR THIS. NOT ADAPTED TO IT.
Most platforms take months and a systems integrator just to go live. Kernopy is different — open by design, connects to your existing stack, and delivers data in days.
| FEATURE | KERNOPY | WONDERWARE / AVEVA | CUSTOM SCADA | SUPER SYSTEMS |
|---|---|---|---|---|
| Live furnace data — no middleware | ✓ | Needs integration | Custom built | ✓ |
| Recipe management & version control | ✓ | Partial | ✗ | Partial |
| Threshold alerts on any process variable | ✓ | ✓ | Custom built | Limited |
| Automated cycle & shift reports | ✓ | Partial | ✗ | Partial |
| OEM-independent connectivity | ✓ | ✓ | ✗ | ✗ |
| On-prem deployment option | ✓ | ✓ | ✓ | ✗ |
| Time to first data (days, not months) | ✓ | ✗ | ✗ | Weeks |
| Open ecosystem & integration capability | ✓ | Vendor lock-in | Depends on integrator | ✗ |
FAQ
COMMON QUESTIONS
Does Kernopy require replacing our existing PLCs or SCADA?
No. Kernopy reads from your PLCs and instruments non-invasively. It layers on top of your existing infrastructure without modifying control logic or safety systems.
Which furnace OEMs and PLC manufacturers are supported?
We support all major furnace OEMs including Ipsen, SECO/Warwick, Solar Manufacturing, and others. PLC support includes Siemens, Allen-Bradley, Mitsubishi, and any device speaking Modbus or OPC-UA.
How long does implementation take?
Typically 4–6 weeks from initial site survey to production deployment. Single-furnace pilots can go live even faster depending on protocol complexity.
Is data stored on-premise or in the cloud?
Both. Kernopy supports full on-premise, hybrid, and cloud-native deployment models. You choose the architecture that fits your security and compliance requirements.
READY TO CLOSE THE GAP?
Talk to Someone Who Knows
Vacuum Furnaces
Not IoT generalists. People who understand AMS 2750, thermocouple channels, and what a TUS survey actually involves.