Aeration runs blind
Aeration runs blind Blowers typically run continuously without feedback control. Driving them from actual oxygen demand is the highest near-term ROI lever in most plants.
Your biggest operating cost is aeration. We optimize it.
Aeration blowers consume more than 50% of a wastewater plant's energy budget, and most run at a continuous, fixed rate regardless of actual oxygen demand. ProcessMiner has proven deployments in industrial wastewater, including a sludge dewatering application that improved cake dryness from 13% to 20%.
Industrial wastewater, specifically
Where the money leaks out of a treatment operation
We work with industrial wastewater sites: facilities attached to pulp & paper, food & beverage, and chemical operations, where treatment performance hits the parent plant's P&L directly.
Polymer overdosing costs twice
Polymer overdosing costs twice Excess polymer isn't just wasted spend. It flows back through the filtrate and disrupts the treatment process upstream, so precise dosing is a cost issue and a performance issue at once.
Regulation is tightening
Regulation is tightening PFAS and microplastics rules are advancing, and biosolids land application is being restricted in Europe and Maine. Timestamped, defensible process data is becoming a legal asset, not just a record.
01 / Demand-driven, not fixed-rate
Real-time optimization of aeration and dosing
The platform predicts where treatment quality is heading and recommends (or automates) aeration and polymer setpoints to match actual demand, instead of running everything at a fixed safe maximum.
- Predictions every 30 seconds; recommendations only when the trend is out of bounds
- Adoption path from advisory dashboards to closed-loop control, at your pace, with operators in control at every stage
Approved visual needed
02 / A focused tag set
Root cause analysis, scoped for treatment
A wastewater deployment typically scopes around 200 process tags, a fraction of a paper machine's footprint. When performance deviates, the platform ranks the contributing variables so the team adjusts the right lever first.
- Ranked contributing factors, not a historian dump
- Works across linear and non-linear variable relationships
Approved visual needed
03 / Built for regulated sites
On-premises deployment
For critical-infrastructure and regulated facilities, the full platform runs on a single CPU-based server inside your network. Nothing leaves your firewall, and every reading is timestamped and auditable.
- No GPU infrastructure required
- Defensible process records for regulatory reporting
Approved visual needed
Measured results
Proven in industrial wastewater
13→20%
Sludge cake dryness
Dewatering deployment result
>50%
Of plant energy is aeration
Typical wastewater facility
~200
Tags per deployment
Focused, fast to scope
<2 wks
To full deployment
Once connectivity is set
Cake dryness figure from an industrial wastewater ProcessMiner deployment. 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 AnalysisPilot-ready
Start with your highest-cost basin.
For qualified industrial pilot deployments, we can supply the sensors and the server. We'll validate against your plant's own baseline and you keep the results either way.
Try our platform
Already seen the platform in action? If you're ready to start a pilot, click below.
Request a PilotSensors and server hardware available for qualified pilots. On-premises deployment for regulated sites.
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.