The project “Digital Galvanizing – reducing waste and lead times” was created with the goal of applying advanced data analysis tools, machine learning, and digitalized operations to improve control of the galvanizing process, reduce scrap, and make production systems more efficient and sustainable.

The initiative led to the development of a digital platform for monitoring and managing galvanizing plant operations, capable of collecting and analyzing process data in real time. Through machine learning and artificial intelligence models, the system can detect potential operational anomalies, improve process stability, and support operators in their daily activities.

The first results are tangible: the platform helps reduce processing defects, improve operational traceability, and optimize resource utilization. This translates into a more stable and controlled galvanizing process for customers, with fewer quality variations over time.

At the same time, process digitalization significantly reduces operator learning times, facilitating the onboarding of new employees and enabling a more structured transfer of technical skills. This represents a key factor in ensuring production continuity and long-term operational reliability.

Beyond the technological aspects, the project has also marked an important step in the company’s organizational innovation journey. As highlighted by Matteo Zanandrea, CEO of Dradura Italia, the initiative stems from the desire to integrate technology and production processes to improve industrial performance and strengthen the company’s ability to face the future challenges of manufacturing. The results achieved so far are encouraging and are already opening new development opportunities. The company is currently evaluating the extension of the digital platform to other strategic plants within the facility, such as the painting line.

From an operational perspective, introducing digital tools into a complex and delicate process such as galvanizing initially required strong engagement with the workforce. Emilia Della Corte, Quality Manager of Dradura Italia, explains that during the early stages of the project some operators expressed concerns about losing control over a process based on very precise chemical balances. Over time, however, perceptions changed: operators began to experience the benefits of the platform firsthand, which now supports their daily activities by reducing the need for manual data collection or for memorizing complex parameters.

Digitalization also helps facilitate knowledge transfer between generations of operators, enabling a more structured sharing of technical know-how and ensuring operational continuity and consistent quality over time. In this way, Dradura further strengthens its ability to guarantee stable quality standards even in high-volume production.

The project was developed in collaboration with the University of Padua, which contributed to the development of data analysis models and algorithms applied to the production process, and AzzurroDigitale, a company specialized in the digital transformation of manufacturing operations and the implementation of technological solutions for industry.

The initiative was supported by SMACT Competence Center, the national center for the digitalization of enterprises that promotes industrial innovation projects.