For successful and consistent casting on ingot DC casting systems, metal heat loss has to be reduced. Metal heat loss is directly influenced by casting trough/launder design and material selection. To assist in developing solutions to reduce metal heat loss from furnace to casting table, Wagstaff® developed a CFD modeling program for heat loss analysis from furnace spout to casting station. The influence of the degasser, CFF units, and automated metal level controls are all included in the program to improve accuracy. Case studies at Wagstaff® R&D facility (DC #1 and DC #6) are reported to reveal the influence of refractory geometry and material selection on metal heat loss.