Process sensitivity
Process sensitivity Small deviations in raw material input, temperature, or line speed propagate directly into product quality. By the time a defect is visible, it's already in the batch.
Precision continuous manufacturing. The platform that proves it.
Nonwovens are a high-precision continuous process where small variation produces large quality impacts. The customers who buy your products, in medical, hygiene, filtration, and industrial applications, have zero tolerance for inconsistency. Neither do we.
The nonwovens problem set
Small deviations. Large consequences.
Raw material substitutions
Raw material substitutions Input changes that look financially viable can destabilize a process. Validating the impact before a change goes live is cheaper than discovering it after a scrapped run.
Zero-tolerance customers
Zero-tolerance customers Medical and hygiene grade failures are not reworkable. A defect is a loss. Prevention, not detection, is the only acceptable outcome.
Why this works in nonwovens
Same concepts, different variables
Golden-run centerlining, root cause analysis, and real-time prediction were hardened on paper machines, a web process with the same structure as yours: continuous formation, drying, winding, and grade changes. The concepts map directly. Only the variables change.
No industry template needed
Models are built from your line's own historical data: basis weight, thickness, tensile, whatever defines your product. Not from paper assumptions.
Grade logic carries over
The same grade-transition logic that manages 5 to 40+ paper grades handles your product changeovers automatically.
Your historian, unchanged
Connects to your existing historian or SCADA in about 30 minutes. No rip-and-replace, no new data pipeline.
01 / The golden run
Intelligent Centerlining™
Every line has a best version of itself. Centerlining compares live production against your best historical runs and gives operators quantified adjustments to hold the process there, which is exactly what a precision web process needs.
- Specific setpoint amounts, not vague alerts
- Separates controllable variables from uncontrollable ones
Approved visual needed
02 / Multi-variable quality events
Root cause analysis
When a quality metric breaches its limit, the platform ranks the 10–15 most likely contributing variables by influence, across linear and non-linear relationships, so a multi-variable event gets a shortlist instead of a war room.
- Ranked by deviation severity and relative importance
- Redundant signals filtered out automatically
Approved visual needed
03 / Before the defect is in the batch
Real-time quality prediction
Predictions update every 30 seconds across the parameters that define your product, so the team sees a drift while there's still time to correct it, not when offline testing finds it after the roll is wound.
- Trend-focused predictions that drive action
- Recommendations every 15 minutes, only when needed
Approved visual needed
Proof from the platform
Measured on webs like yours
Nonwovens is an expansion vertical for us, so we quote cross-industry results, not invented ones. Here's what the same mechanics have measured on continuous web processes.
>20%
Quality variability reduction
Pulp & paper deployments
30s
Prediction cadence
Continuous, live
~30 min
Historian connection
Existing infrastructure
<2 wks
To full deployment
Once connectivity is set
Figures reflect actual ProcessMiner deployments in other continuous-manufacturing verticals. Results vary by facility, process, and data quality; past performance is not a guarantee of future results.
How implementation works
Start with proof. Scale on results.
Every new customer follows the same staged path: a free analysis of the data you already collect, then a 60-day pilot on live production. From there, you expand as the results earn it. You set the pace.
Pilot program
1
Start here
Free Analysis
Includes
- Offline PM Studio dashboard from your historical data
- Data healthcheck of what you capture today
- Findings reviewed with your team
2
Live Pilot
60-Day Pilot
Includes
- Live PM Studio dashboards on your process
- Real-time monitoring of trends and drift
- Prediction, root cause & centerlining
Enterprise license
3
Stage 1
Predict at scale
Everything in the pilot, plus
- Full deployment across your operation
- Annual assessment of value delivered
4
Stage 2
Guided action
Everything in Stage 1, plus
- Prioritized recommendations operators can act on
- PM AI Agent for plain-language answers
- Value capture tracking
5
Stage 3
Autonomous optimization
Everything in Stage 2, plus
- Closed-loop control writing setpoints back to your systems
- Trial vs. production analysis validating every change
Most teams enter at the Free Analysis, but you can step in wherever fits. How far you take it depends on where your operation is today.
Start with a Free AnalysisPrecision deserves proof
See how the golden run maps to your line.
Bring your quality metrics and six months of historian data. We'll show you what the models would see, then decide together whether a pilot makes sense.
Historian connected in ~30 minutes. Full deployment in under two weeks.
Get in touch
Have a question?
Whether it's our platform, your process, or a pilot you'd like to see in action, let us know.